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wndsnd wndsnd is offline
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Join Date: Jun 2010
Location: Massachusetts
Posts: 332
I had to fabricate

Well, this isn't the easiest of repairs. I think I have some pictures here but the fender is double layered up there, welded, and filled with inches of rock solid seam sealer and dirt, mud, etc.


This is what I stared with, not a pretty site. I looked around but found other donor cars were just as bad, but the time to take a piece from another is just as bad as fabricating.


I cleaned thing up and cut out the rust back as far as I needed to get to strong metal.



I tried making templates out of cardboard and plastic but It didn't have the properties I needed. I ended up getting the thinnest sheet steel I could find, I believe it is 24 Guage, and I was able to work that and modify it to my satisfaction. Once I had a templace I thought was acceptable, I duplicated in 18 guage.

Now I have a rough fix. I still need to work from under the fender to seal things up and also to adjust the door gap, but there were a lot of little parts that needed to be welded to make the whole.







Good luck, take you time, it can be done, but it will take time...
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2006 997.1 Carrera S Cabriolet
Old 05-06-2012, 06:39 AM
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