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How to Repair a Rusty Fender

Don't Throw Away That Rusty Fender. We'll Show You How To Easily Revive That Sacred Sheetmetal.

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Paradis used a straightedge to mark cut lines in the original fender for removing the rust and leaving only solid metal. To make the repair easier to accomplish, he cut roughly 11/44 inch inside the fender edge next to the door and the same distance inside the fender lip to preserve these complex, curved surfaces. This also improves structural strength. He also retained the bottom edge of the fender even though it was heavily rusted. The patch panel did a good job of reproducing the lower edge, including the rectangular opening for the fender bolt.

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