Main British Car:
1972 TR6 1994 5.7 L GM LT1
Ken Hiebert's 1965 Jaguar E-Type with GM LS1 V8, "Part 7"
Posted by: TR6-6SPD
Date: April 04, 2019 01:09PM
Here is a link to "Part 1" of the project:
Here is a link to "Part 2" of the project:
Here is a link to "Part 3" of the project:
Here is a link to "Part 4" of the project:
Here is a link to "Part 5" of the project:
Here is a link to "Part 6" of the project:
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Lower rear fender repairs
These areas were rusted out, non-existent.
After installing the outer sills, I left these voids until I was further along into the fenders. Now was the time.
Left and right side, before and after:
With the 1/4" rod firmly in place representing the fender lips, I formed a few fender shapes in cardboard to see what I liked and would work with tire clearance.
Shaped 1/8" rod:
Cardboard taped in place:
After finalizing the end shape, I decided to go with four small panels in the middle and two larger ones at either end. The five 1/8" rods would mark the butt weld lines with the end panels lap welded to the body.
Final trim and body prep:
Wheel at full jounce with 1/8" rod providing fender clearance:
Wheel at ride height:
Now it was time to just fill in the blanks. I recorded the length and shape of each 1/8" dividing rod to carry over to the left side. The paper cut outs confirmed the panel sizes side to side:
Front panel formed:
Rear panel installed:
Center panels going in:
Finished for now:
With wheel at ride height:
Left side done:
Several different panels on each side were needed to join what was left of the old inner panels to the new fender. It may have been easier to complete this when the body goes on the rotisserie but I wanted to get it out of the way.
Panels cut and installed:
The doors on this car were in tough shape. After I removed the door skins, (heavy with filler and rust) I sent the inner doors, (shells) out to be acid dipped. This removes all the rust. Not much came back.
The structure of an automotive door is quite standard in the industry. You have a shell which the hinge is mounted to and it has flanges which the edges of the door skin is folded over on.
These door shells would need new hinge mount assemblies and flanges replaced where needed.
Door shell mounted as a test fit:
Typical flange destruction, top front corner:
Bottom front and hinge mount assembly damage:
Hinge mount assembly removed:
New assembly fabricated:
Edited 4 time(s). Last edit at 05/23/2019 02:55PM by TR6-6SPD.