Rust repairs.

I cut away the piece of trunk floor that connects the trunk floor to the quarter panel.  The plan is to try and rebuild this part to look close to factory made. Measures can be taken from the left side witch is in better shape and re fabricate right side part to resemble.

In order to "mirror" the part from the left side of the car a template out of paper was made.

Something like that.

I wanted to try and make stiffening beads to the  repair piece! Not that they are needed but would look nice. Should have made the beads before bending the plate!

Made a groove in a piece of plywood and tried to form the sheet metal by hammering and using the plywood as mold.

The result was terrible!

In an attempt to rescue the situation I called a friend with a bead roller and went over to him and made the beads now the problem was that I had bent the repair piece witch limited the movement when using the bead roller. 

Well now I have beads not exactly as on the original piece but they will have to do!

Hammered the "lip" that connects to the quarter panel on free hand towards a piece of wood! As the edge of the metal is not in a straight line it causes the piece to get bent.

I don't have tools for shrinking and stretching sheet metal so the "lip" was cut to enable bending as needed.

Mocked up. It Looks OK!

Before welding in place the surface that will be facing outwards towards the quarter panel was painted with rattle can spray for rust protection as it might be hard to access later on.

Tack welded in place.

I wanted to try and make a "real" repair piece although this part will not be visible on the couch. The piece came out far from perfect but I'm still quite happy with the result.