'66 Sunbeam Minx Project - F20C/6sp/4-link/Discs...

[Frizzle Fry]

Here's the extent of the previous bondo job:

Originally Posted by Kristian j

When you did take that front end away, I suppose you noticed the "shelf" at the end of the wing, just below the windshield. The serious rost spot on that body. Mud and gore stay there and the front wing rust from the inside. I usually put an inner ving on my cars to solve that problem. But maybe you live in a dry climate.

This is the spot you are talking about. It had a rubber seal/dam riveted in place that I removed:


This area has haunted me ever since I discovered it. I knew it would be a nightmare to clean/seal. Well, I spent a good 5hrs cleaning and sealing the inside of this fender, including that area. The extra access afforded by the removed fender section forced me to do it now.

Here you can also see the fender rolling I had done previously vs. the new un-rolled section:


Same with the inside of the donor section (zinc primer on the joint edges)


But first, how I determined where to cut the donor part:








Free at last. This pic was actually taken to show the spot welds that had to be drilled out with a spot weld bit:


Test fit, trim, fit, trim, fit, trim, fit, trim...


Inverted fender roll:














Test fit grille:


So the fun part is done