This 6.3 had been patched in the past but unfortunately a drain hole was left out .The tail lights were not installed properly and water leaked in, rusting out the previous repair .
Holes appeared in the side of the rear quarter.
After the bumper was removed the paint was ground off and lots of body filler was revealed ,which in turn covered more rust.
The bottom of the 1/4 Box was unpicked and yet more rust and dodgy repairs uncovered. this is inside the box looking up from underneath.
The box bottom and the section from the chassis rail were removed to get rid of all the rust.
The Support bracket has been repaired in the past but had rusted out again ,then repaired again
Compared to the new pArt there is a lot of difference …….
New panels were made up to replace the damaged parts. At this point the outer skin hasn’t been removed .
A new section has been welded in to replace the rusted section
Followed by a couple of coats of etch primer then seam sealer.
The Right rear section ,when paint was stripped off revealed more damage .The yellowish parts on the panel are bronze from the previous attempt at repair .
The ruler indicates hte depth of the dent
Right rear edge of the boot lid is 10 mm too high,indicating hidden damage.
left rear edge of boot lid fits closer and factory correct.
The bootlid sits high along this edge too, because the fender edge has not been straightened properly in the past and will have to be lifted up.
The Difference in the panels
The new rear Box for the panel has been fitted and welded into place .
New outer skin is being welded into place .
At the ‘C’ Pillar further damage from a past accident has been revealed so this will need to be straightende out ,Once the rear window was removed, further rust has been revealed because the rubber seal had not been fitted properly and moisture had leaked in .
Rist in the base of theC pillar .
Inside the C pillar section at the parcel shelf it has rusted quite badly .
Rear panel is badly dented and bad repairs in the past were hidden under a layer of cheap body filler .
Yellow lines out line some of the Dents which have to be repaired before the Side panel can be fitted to the car..
With some of the dents removed . the extent of the distortion is revealed by the piece of wood .The arrows indicate where the panel is leaning back, where it should be leaning the other way.
This is the fuel pump cover which was dented and rusty after 50 years under the car, being bashed by rocks and bad driving..Now straightened out and repainted in the correct Satin Black.
Once the lower part of the right rear quarter was remove rust in the wheel house was discovered ..
The rust removed and repaired in this place .
Rust in these places is unfortunately very common ,as the boot lid hinge pocket has a drain which dumps into the base of the rear roof reinforcement. in Australian built cars such as this they rust because it was bare steel .In the above pic the rust in the base has been repaired with new steel.
At this point I checked the condition of the remainder of the panel and even though I spent several hours attempting to straighten it,it was obvious that it looked OK from a distance but is damaged beyond repair .
The only option was to remove the damaged remnants and repair further rust on the wheel house .The bulge in the panel is a result of tension /pressure caused when the car has been hit in the rear at some time in the past. The rear panel will probably have to be replaced too as it appears to have also been roughly repaired .
the Roof support beam can be seen here and where it is welded to the wheel house it has rusted and been repaired.
The Lower part,on the wheel house opening was also replaced as water collects there, dirt builds up and this had caused more rust .It was beginning to come though the fender skin . The wheel house was also damaged in the accident and had to be bought back into shape
So ,with that i had to make a complete new skin to replace the rusted and dented parts.