'93 Civic Si - rust repair and repaint project

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PostPosted: Thu Jun 10, 2021 10:01 pm
This was a project I started fall of 2019 and completed summer 2020. The car is owned by my adult daughter. She bought the car 6 or so years ago. At the time she bought it it had a terrible paint job, lumpy body, and as we later found out rust holes filled with filler. But interior and mechanical great and being original Si we deemed the car worthy of body repair repaint.

Here is how the driver side quarter panel looked when daughter handed car over to me for repair:

IMG_20191014_161717.jpg
Rusted driver side 1


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Rusted driver side 2

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PostPosted: Thu Jun 10, 2021 10:12 pm
So cut the rust out of the quarter panel. Parts of the inner wheel also had to be cut out until all rusted areas were removed:

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Cut out rust 1


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Cut out rust 2

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PostPosted: Thu Jun 10, 2021 10:18 pm
Next was slowly cutting quarter panel to fit patch panel. This took a lot of time so slowly get good fit:

IMG_20191020_144417.jpg
Patch fit 1


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Patch fit 2

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PostPosted: Thu Jun 10, 2021 10:23 pm
Butt welded patches in rear lower wheel well and the upper rear area.

IMG_20191023_212220.jpg
Patch 1


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Patch 2

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PostPosted: Thu Jun 10, 2021 10:27 pm
PPG Epoxy primed inner wheel well after metal repair:

IMG_20191102_170114.jpg
Prime 1


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Prime 2

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PostPosted: Thu Jun 10, 2021 10:30 pm
The patch panel was bonded into place along the lower body seams. The patch was PPG Epoxy primed. Weld through primer on both patch and quarter panel along edges for later welding.

IMG_20191228_135023.jpg
Bond 1


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Bond 2
Last edited by 69cuda340s on Thu Jun 10, 2021 11:53 pm, edited 1 time in total.

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PostPosted: Thu Jun 10, 2021 10:33 pm
Patch bonded to vehicle.

IMG_20191228_140750.jpg
Patch 1


IMG_20191228_141204.jpg
Patch 2

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PostPosted: Thu Jun 10, 2021 10:36 pm
The patch was bonded onto car in fall of 2019. Around March 2020 when weather was just starting to warm I welded patch to quarter panel. Note tin foil taped to glass to protect. It is best to protect glass during any grinding or metal cutting to prevent damage:

IMG_20200309_114538_01.jpg
Welded 1


IMG_20200309_141432_02.jpg
Welded 2

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PostPosted: Thu Jun 10, 2021 10:45 pm
Passenger's side only had a couple rust bubbles here and there. But since we did not want to come back and repair rust later it was decided lets just cut it all out like on driver's side. No inner wheel well work was needed on this side. Note how I stripped paint off outer panel before I cut to size. This was to avoid heat and metal warping and least that was the idea.

IMG_20200322_173538_01.jpg
Cut out


IMG_20200329_150913.jpg
Primed

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PostPosted: Thu Jun 10, 2021 10:47 pm
Passengers side bonded and welded in:

IMG_20200404_130008.jpg
Weld 1


IMG_20200404_173315.jpg
Weld 1
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