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Front Fender Replacement
Posted by: Bill Warren ()
Date: September 03, 2017 07:22AM

The PO used an old school method to pull the dents from this fender then left the car for 20 years. I have a nice fender for replacement but I'm not sure where to cut. I'm look for advice from someone who has been there done that.Thanks!

Bill Warren
Decatur, AL
65 Corsa
68 Monza
65 Monza

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Re: Front Fender Replacement
Posted by: American Mel ()
Date: September 03, 2017 07:41AM

WoW ! ! ! eye popping smiley
I have seen that done before, but not to that extent!sad smiley
Looks like that fender was hit by a ton of those very rare metal termites!grinning smiley

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Re: Front Fender Replacement
Posted by: gnvair ()
Date: September 03, 2017 07:44AM

Bill,
They can be time consuming to remove.
Besides drilling spot welds out along the wheel opening, gas filler pocket and rear edge near the door hinges. You have to remove the lead at the joint below the windshield. There will be more spot welds there.
Saving the weatherstripping channel is the most difficult chore as there are a lot of spot welds on that piece.
Another hard spot is getting to the spot welds where the lower front panel meets.
If you aren't saving the old fender I would recommend just cutting the fender off in that area and then removing the remnants after.
Harbor Freight sells inexpensive spot weld cutters. I have used them and they work just as well as the expensive ones sold by body shop supply houses.

Lee J

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Re: Front Fender Replacement
Posted by: MattNall ()
Date: September 03, 2017 08:10AM

How many holes in the skin? Those are Stud weld marks?

I'd blast / Convert seal and then skim coat it and start block sanding.... if it's not intended to be a Show car!





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Sea Mountain, between Charleston Harbor and Coos Bay! SW Oregon Coast
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Re: Front Fender Replacement
Posted by: RexJohnson ()
Date: September 03, 2017 09:47AM

If the fender is still solid and they did a good job of straightening it I would just weld up the holes. Yes it will take a little time but not as much as it would to cut off the old fender and to properly fit a replacement. If you do weld up the holes make sure that you mark any emblem holes that should not be welded so that you don't have to drill them back out.

RJ tools
Salem,Oregon

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Re: Front Fender Replacement
Posted by: Frank DuVal ()
Date: September 03, 2017 01:01PM

Since the backside of this area washes with water going down the vents in front of the windshield, just plastic filler (Bondo et all) will act as a sponge and it will rust back out.

Welding holes good. But warp will not be your friend.

Soldering holes closed , 1/8" holes solder well, larger not so much. Nice and waterproof.

Quick and cheap? Tiger Hair or other fiberglass resin product over epoxy primed (PPG DP series) steel works.

Frank DuVal

Fredericksburg, VA

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Re: Front Fender Replacement
Posted by: jjohnsonjo ()
Date: September 03, 2017 01:17PM

The problem you have is there will be lots of rust started on the back of the panel, so no matter what you decide you must get behind it and get rid of the rust first and then protect it. Brazing may work, also Marine Tex which will absolutely NOT absorb water.

J.O.

65 Corsa Turbo Vert
79 Honda XL 500S
69 Honda CL 160 D
2010 BMW F 650 GS
2003 Bounder 36D
2013 KIA Optima SX turbo-AKA ZIPPY (wife,s car)
69 Newport Holiday Sailboat
Baja 150 dune buggy cart
Coleman HS 500 UTV
2016 KIA Sorento SXL Turbo

Bethlehem,Pa

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Re: Front Fender Replacement
Posted by: The Stig ()
Date: September 03, 2017 01:40PM

I'd be inclined to try what Rex suggests. Weld 3or 4 holes shut at a time. Jumping around to not build up heat. Then break to let it all cool. May be a bit tedious, but a lot less work then replacing the whole thing.

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Re: Front Fender Replacement
Posted by: bought1 ()
Date: September 03, 2017 02:15PM

I'd weld them up too but do not too may adjacent ones at once. The heat will warp the fender.

Dave

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Re: Front Fender Replacement
Posted by: Huntsville ()
Date: September 03, 2017 04:29PM

I've seen that fender, there are probably over 500 holes in it!
You could spend the same amount of time or less replacing it and have a better fender.

I'll sell you one cheap, Bill, but you'll have to remove it yourself!



Danny Robertson
Huntsville, Al
'64 Spyder (Daily Driver)
'63 Rampside (Rotisseried and in Progress!)

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Re: Front Fender Replacement
Posted by: MattNall ()
Date: September 03, 2017 04:33PM

He already has one!! ggg





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Sea Mountain, between Charleston Harbor and Coos Bay! SW Oregon Coast
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Re: Front Fender Replacement
Posted by: MoxyRamone ()
Date: September 03, 2017 05:53PM

As a body man, I would opt for replacing the fender. There are about a billion spot welds, and yes, it's a pain in the butt, but at least you won't constantly worry about it rusting out. Welding all those holes will just warp the panel. Tiger hair will fill it and doesn't absorb water, but you'd have to use a lot for that Swiss cheese panel. They got it straight but removed half the metal with all those holes.

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Re: Front Fender Replacement
Posted by: Bill Warren ()
Date: September 23, 2017 01:22PM

Owner of the car decided to remove the fender.I supervised and documented.

Bill Warren
Decatur, AL
65 Corsa
68 Monza
65 Monza

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Re: Front Fender Replacement
Posted by: Murphy ()
Date: September 23, 2017 04:51PM

To me this is the best way of doing it, nice work.

65 Monza Coupe
61 500 Coupe (under Construction) Getting close.

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Re: Front Fender Replacement
Posted by: kenzen ()
Date: September 23, 2017 05:23PM

Make sure you put the door in and get the gap right when you refit the new fender!!!

kenzen
66 Monza Coupe 110/PG
Bel Air, MD

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Re: Front Fender Replacement
Posted by: BobV66Vair ()
Date: September 24, 2017 09:49AM

Nice dedication to doing it right. Couldn't you just cut near the edges of the panel and leave the spot welds? Then weld the new fender in place. Sounds like the spot welds are the time eater.

I have always wondered why the inside of that whole area does not rust more since water is allowed to run inside the fender from the cowl area. Seems like a terrible design to allow water inside the sheet metal like that. I am considering closing up the whole area under the cowl on my race car. Stop air pressure from building there and force it over the car.

Bob Vinnacombe
Sandy, Oregon
1965 Corsa 140 stock
1966 Monza Soon to be race car
1968 Monza Parts for now

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Re: Front Fender Replacement
Posted by: MattNall ()
Date: September 24, 2017 09:55AM

Welding that much seam causes warpage as well..


The Drain design works well if kept clean!





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Sea Mountain, between Charleston Harbor and Coos Bay! SW Oregon Coast
Click HERE for My Website...Click HERE for My TechPages!
..............................110-PG.................................................Webered-Turbo

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Re: Front Fender Replacement
Posted by: rowin4 ()
Date: September 24, 2017 10:06AM

OK, how much time did it take? Cutting the top off the fender to avoid the windshield area was a good idea. Are we going to have a documented install ?

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Re: Front Fender Replacement
Posted by: MoxyRamone ()
Date: September 24, 2017 10:12AM

This really is the right was to do it. Can't wait to see the results!

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Re: Front Fender Replacement
Posted by: Bill Warren ()
Date: September 24, 2017 11:46AM

It took about 5 hours to cut the fender off. The owner had a drill bit and chisel for cutting spot welds.His goal is an undetectable fender replacement. He has a nice replacement fender but it may take a few weeks to get to putting it on. The car is a very nice Corsa 140 with AC. I'll show replacement.

Bill Warren
Decatur, AL
65 Corsa
68 Monza
65 Monza

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