Installing new metal in rusted areas is a bit time consuming, but not difficult. After cutting out the rusted area, the new panel is cut to fit and tack welded in place. The patch panel is then stitch welded and ground down almost to the level of the new metal. Although it will never be seen a small amount of filler will be used to level the area before the primer is applied.
To properly align the new rocker panel, the door and both fenders were installed. This is done to assure proper margins between the door, fenders and rocker. Since the lower part of the body will be a contrasting color, a great deal of attention must be given to keeping the body line straight.
After the rocker is aligned and tacked in place, it will be spot welded as it was originally. After the new panels and areas surrounding them are sandblasted, the new rocker will be sealed on the inside to prevent rust. Although I suspect, this car will never see a drop of rain.
I must take tomorrow off to rest the body, but work will resume on Monday morning.
Enjoy,
Tom McCurry
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