Fall 2004 - Passenger side rear inner fender replacement:
The front inner fenders were completed. The bottom of the A pillars have yet to be fabricated.
At the same time, the driver's side, which was equally bad, was also replaced.
After the front, I decide to tackle the rear inner fender where the B-pillar attaches to. Most of the entire panel was covered with heavily pitted surface rust. The B-pillar also had a few holes.
The original plan was to save as much of the B-pillar as possible and just cut out the verticle portions that were heavily rusted. However, the interior of the B-pillar had serious rust problems and the whole thing needed to be cut off. I'll source a new B-Pillar from Moss.
I kept on cutting away rusty metal until not much was left. I basically cut off everything except for the trapizoid piece that sticks out about an 1/8 of an inch. I would have replaced this also but I couldn't replicate the indentation.
Once the rust was cut away I started fabricating. As you can see I cut around the indentation. There is a curve in the panel that I replicated by cutting the patch and installing another L-shaped piece. In this picture there are 4 seperate patch pieces.
This picture shows the curve of the part of the panel that the B-pillar attaches to. Since I couldn't replicate this out of one piece I used an L-shaped piece that I welded into a slice in the verticle panel. This replicated the curve quite well. All this will eventually be hidden by the B-pillar and the rear fended. A coat of filler on the inside will cover the seams and the repair will be invisible from the inside.