Part 34. More work on side panels

Today we finally finished welding the passenger side of the car. Just a few pieces left.

First I cut off the rusted side panel bottom section.

panel

panel1

Fitting a patch for the beam:

panel2

panel3

Patched! There will be three layers of sheetmetal at places, so no need for 100% welds.

On to making a new bottom for the side panel:

panel4

I think that often the best metal for an old car comes from another similar car. The steel is same quality, thickness and has the same bending/stretching characteristics as the original. Often times modern sheetmetal is tougher/harder than the original, which can be problematic when you try to reshape a patched area.

Also 96 has some parts made of very thick sheetmetal – one can’t use a 1mm plate to patch a 1.3 mm plate etc. so you would need various sheets at different thicknesses in stock.

There’s plenty of junk Saabs left – the above piece I cut from the roof of some 96 stroker – just find a rust free spot. (…also, recycling is much cheaper than buying new sheetmetal!).

Finding the basic shape.

panel5

panel6

panel7

panel8

The patch in correct shape after 3 hours of fitting and banging and bending and fitting and…

panel9

panel10

panel11

After cleanup:

panel12

And then the inner fender:

inner1

Seems to be something missing here… 😉 Patchmaking in progress.

inner2

Done, finally!

inner3

inner4

A small sand blaster is great for cleaning up slightly porous welds and other tight spots.

sandblast

And the primer:

sidepanel1

sidepanel2

sidepanel3

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