Wow... just wow...

Here is the guard with the arch glued on well solid, so now it's clean off the excess glue and rough up the panel with a DA sander + 60 grit paper. The arch was a bit feathered at the edges so they were blended back with the flapper wheel, that's what the blue dust is from.

Ha, this rust hole was previously bogged with a piece of ice-cream container and a zip tie, I did weld a patch there but not very well, it was just to stop the filler falling in !

The closing panel got welded back in as close to how it was from factory and while I was there I welded in a reo-mesh piece to stop the panel warping out going out of shape when it's being fglass molded.
This is after an rvo of bondo sanding and refilling till I was happy, first part I did was the top, as you do, it's got rattle can primer but the sides are still being worked on .

And finally the other fibreglass guard is resting on the car, it'll need a bit of fetling to fit correctly as with any fglass part


Sort of been bouncing between the Rally Pack and my car, some work done on the RP was weld on the floor repair piece and refit the seat box rib, then it was repair the wheel well at the middle seam. Next on the list is repair the rear arch corner. Then the final rust repair is to make a boot floor panel to replace the sketchy one that's there now. Have bead roller, will fix, tho I had to sacrifice a set of dies to match the curved ribs, we see how this one pans out soon....

Pulling the door out of the spare room I didn't realise how dented it was and since I paid to get them blasted and coated last year I'm going to do what I can to get it straight

And here is sunken along the middle of the door skin, narsty !

Always admire your fibreglass work Marty. It's definitely something waaay out of my skill set. My only experiences were as a late teen/early 20s fixing holes on cars before I knew any better and/or owned a welder! Pretty sure I got more in places that it shouldnt and more on me than on the repair.... great to seeing it used as it should.

That's the Vevor dent puller right? Remember it from earlier posts.

My wagon has a dent/crease across the rear door which I can't get to from the inside. For the price, I think I'll have to give it a go.

Shaun

👍👍 a lot of work

you might need to put your order in for topcoat soon Marty.

I won't bore the audience with the door story, but happy to say it's just about done.. Both sides !

The long sander is a AliExpress special at $15 ,I bought a spare. I also use a 450mm monster block with a Velcro mod done to attach the paper to


My car has the oval boot plate plugs removed, well they kinda just pushed out, I was going to reuse them after a session in the blaster but thought to make a set instead

They aren't exact copy but I wasn't bothered, even flat would do but if I get a chance to spin the bead roller I will. They came up a little wobbly so some hammer and tweaking to the sealing edge until flat then they was stuck down with Sika.

Thinking for later cause I'll possibly be throwing some colour in some places soon (I need to catch up and overtake Dave's Garage) in the boot and underside first, there's still a battery mounting and spare wheel mount to consider. The battery will be a gel dry cell so I don't need to box it in an ugly boat battery box . Plan is to make one like the orange Mex has in ally . The spare wheel will be a space saver from a Focus or Fiesta and will lay flat, 1 option is similar to modern cars with the packing foam with shaped pockets for jack and tools or whatever if this is the way I go the tyre needs solid mounting . Might need to check wrecked cars for ideas... If your daily has the foam in the boot please send a pic..

Haha, yeah when he ran out of the car saying I need the mask quick had me smiling, just the way he reacted lol.
He's pulled some dents out here n there and he's starting to move along a bit faster now with the car. If mine wasn't as bent up I'd have it done a year ago and that's what makes it a project .
If Dave Garage is watching, chime in and say hello !