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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.
By Jeff Smith
Photography by Jeff Smith
Rust Repair Panels
The majority of the work entails trimming and shaping both the original fender and a simple patch panel.
Rust Repair Panels
What we started with was a monkey fist-sized rust hole in the bottom of the trailing edge of both front fenders. Note that the reinforcement panel behind the exterior sheetmetal has also been sieved. We're going to repair that panel as well, but we'll save that procedure for a later date.
Rust Repair Panels
We purchased two fender-patch panels from National Parts Depot to begin the process. The panel is great because it's actually thicker than the original sheetmetal. But as you can see from this photo, while stamped in the general shape of the lower fender, it is slightly longer than the original. This is OK because we're only going to use the center portion of the panel anyway.

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