Rescuing Ruby, Extensive Quarter Panel Rust Repair

[SEgirl]

That's right, I forgot you had the cashmere coupe. Stinky could be your first sedan and Geneva Green :-)

Would be my first SE sedan. Rescued a 93 SE coupe a couple years ago.

[Fleetw00d]

Am I crazy? Yes, the quarter is rusty, but the frame box section looks intact; cut it almost down the center of the trunk floor to get the structure under this side. I have a set of rust free quarters. Took about two hours - someone else had removed the rear bumper and rear of the interior (might have been me about a month ago - I started on it, but it was just too cold that day). Sawzall battery gave out before I was finished cutting, had to cut the C pillar with a chisel. I'll cut away some pieces I know I don't need, then maybe have it stripped to remove all the undercoating and such before I start undoing spot welds and figuring out how to take it apart to figure out how I can put Ruby back together (again!).

20210327_100806_resized by Paul Kemme, on Flickr

20210327_105719_resized by Paul Kemme, on Flickr

20210327_110551_resized by Paul Kemme, on Flickr

[hiptech]

"Am I crazy?"

I'd say YES! Crazy as a fox!!! Just goes to show you'll never get "CB7 Fever" out of your system

I wish I had your determination and wherewithal to do something like this. Damn, it would be hard enough to accomplish this under ideal conditions but out in the field... you are awesome and we're not worthy!!!

BTW if you ever come across a top plastic steering wheel column cover (in pristine condition) let me know...

[SSMAccord]

It always frightens me when I see cars cut like this in salvage. I’m glad you were able to find useable parts though.

I cannot imagine cutting through with a chisel. Good work!

[Fleetw00d]

It always frightens me when I see cars cut like this in salvage. I’m glad you were able to find useable parts though.

I cannot imagine cutting through with a chisel. Good work!

Frightens you in what way? All the dangerous sharp edges (only a couple small cuts on fingers, elbow), or that someone is going to attempt to use parts like this to repair their car?

Sharp edge on a thin chisel. Took maybe 5 minutes(?) of hammering on it. The saw scared me because it just quit; didn't slow down, just quit. Grabbed my battery on the way out, plugged it in and it worked. There may be something that cuts it off if it gets too hot.

The quarter section only cost $65 - worth that much to me to figure out if I think I can repair Ruby.

[SSMAccord]

I dunno lol. It seems like a really invasive surgery.

[PakaloloHonda]

INcredible man ... I'm siding with hiptech, lol ... sooo not worthy! I have done nothing in my life... lmao!
Fleetwood ... you are the Elon Musk of CB7's ... Bring Back Ruby!!!!!!!!!

[Fleetw00d]

I dunno lol. It seems like a really invasive surgery.

So are heart/lung transplants.

[deevergote]

That’s awesome, Paul!

[SSMAccord]

So are heart/lung transplants.

LOL. This is what I was equating it to in my head!!!

[Fleetw00d]

I guess I already did the heart transplant, installed the A6 about 60K ago.

More photos; time to start trimming.

20210330_192059 by Paul Kemme, on Flickr

20210330_193342 by Paul Kemme, on Flickr

[hiptech]

Too bad there isn't some new breakthrough in technology coatings that could be applied to the entire replacement assembly to prevent (or at least slow down) future corrosion?

[Fleetw00d]

Studied the chunk of quarter panel to attempt to figure out a way to replace the quarter without splitting the wheel well opening spot welds. The weld joint between the inner wheel housing and the floor is actually below the floor and exposed from underneath. It appears possible to split the seam between quarter and the trunk floor all the way from the rear almost to the front from underneath and be able to redo most of that with my spot welder. Need to explore the front portion a bit more. At the top, I can separate the quarter from the rear shelf. Another tricky part would then be the C pillar. I think I can get the frame box sections from this piece, but I would need full quarters to replace the entire wheel housing at once; the quarters I have only include the outer half of the wheel housing. Anyone know of a rust free sedan shell in a salvage yard?

Wire brushed to expose the spot welds where the lip of the floor is welded to the inner wheel housing.

20210417_173714_resized by Paul Kemme, on Flickr

Looking down with the piece of the rear shelf removed (other than a small section at lower right).

20210417_171216_resized by Paul Kemme, on Flickr

[Fleetw00d]

How tough is it to learn to use an arc welder? Some of the the areas on the original body appear to have been welded with an arc welder, not spot welds? Local Rent-a-tool place has one available. Might be handy for places I won't be able to use my spot welder to put her back together.

[Raf99]

wow. In that last pic I can't even tell what I'm looking at. But I was thinking this metal is so thin a small little mig welder will do. That lower trunk part will take some work as well, thin and will warp easily. Plus, can one put the OEM sealer on there i know last time I had my car in they used same type of material but put it on top. So your plan here is to trace it out (somehow?) and cut back 1". Then tack together or cut so all points are even and weld?