Cut out a small rusted area on the front of the cowl. Then when I was media blasting it a few more holes showed up.


Here you can see the larger cut out for the patch. Fabricating this patch was a bit difficult due to the rounded corner.


Forgot to take a picture of the patch tacked into place. Here it is with 2 coats of epoxy primer brushed on.


I media blasted the rust inside the cowl vent surround area and brushed some epoxy in there at the same time.


Plan to fabricate the patches for the vent surround next.

Fabricated the lower cowl vent surround patch today:



Brushed on two coats of epoxy primer, tomorrow I will seam seal the inner edge and then fabricate the patch to close it all in.

Nice work
I have had to do the blast inside and brush it a few times, It works.

Got the outer patch fabricated and installed.
Didn't have time to get epoxy primer on since it will be in the mid teens tonight and I really didn't want to heat the garage all night.

Installed the inner fender supports and fenders to check panel alignment.
Driver's side looks good however the passenger side rocker panel did not.
It appears to be narrower at the front. I had noticed that when installing and tried to cheat the gap at the floor panel (where the door seal goes) a little bit to correct it but that wasn't enough.

So I made some cuts in the metal and widened the top portion about 1/4".


Reinstalled the door and fender and began pulling dents:


The wheel arch on this fender was in real bad shape to begin with:


Made good progress on it but needs a bit more shaping once I remove the fender.

I would Pull the inner fender well out and work the lip on the Truck as Much as possible before removing it.

That's a good idea. Thanks.

Nice job on all the rust repairs

Media blasted the fender so I could see the metal better:

After some filler work and two coats of epoxy primer.





This was the worst of the two fenders and had the puncture in the top, ripped metal and dented wheel arch.

Started pulling dents on the lower bed: