'95 Civic EX 2Dr - rust repair repaint project

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PostPosted: Fri Jul 16, 2021 12:03 pm
Fabbed up lower rocker panel piece and welded in:

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Rocker Panel Test Fit


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Welded

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PostPosted: Fri Jul 16, 2021 12:12 pm
Fabbed up and welded in rear lip where patch meets bumper. Still need to grind the patch down slightly to fine tune gap between patch and bumper cover but I will do that once patch is bonded welded in:

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Piece tacked in
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Piece welded in
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Bumper screw
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Bumper test fit

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PostPosted: Fri Jul 16, 2021 12:19 pm
Welded two small rust holes shut on front area of wheel well lip. Also welded in a 1/2 x 1 inch patch to repair rusted area. Hammer and dolly the wheel well lip straight.

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Patch welded in


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Wheel well edge lower front

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PostPosted: Mon Jul 19, 2021 9:01 am
Some rust was present in lower rocker panel area forward of the patch. Too much rust to spot repair so that area was cut out.

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Rocker Rust
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Rocker Wired Wheel Down
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Rust Removed
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Light inner surface rust

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PostPosted: Mon Jul 19, 2021 9:09 am
Wire wheeled surface rust down on inner structure. Hand fabbed a patch and welded it to the larger patch. This way one patch will be installed for wheel well and rocker panel areas:

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Wire wheel inner surfaces
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Rocker patch 1
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Rocker patch 2

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PostPosted: Mon Jul 19, 2021 9:15 am
A lot of rust pieces fell into inner rocker panel/frame rail. I was able to vacuum out and push out through drain hole. Important to get all of that cleaned out so it does not trap/retain moisture:

PXL_20210718_162050579.jpg
Debri in rocker

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PostPosted: Tue Jul 20, 2021 9:57 pm
Removed patch and cut holes for molding fasteners. These square holes were cut from the back side with a small cut off wheel in dremmel tool.

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Molding click holes
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Rocker molding test fit

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PostPosted: Tue Jul 20, 2021 10:00 pm
Cut square hole in patch for body side molding on driver side. Test fit body side and rocker moldings on driver side.

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Molding test fit 1
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Molding test fit 2

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PostPosted: Tue Jul 20, 2021 10:17 pm
Now moving on to rust behind passengers side rear wheel. This panel is ribbed and has a complex shape. Turns out the 4 door sedan from same era has the same panel. So found one in a local pick and pull for $10 and cut it off the car.

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Rust rear pass side 1
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Rust rear pass side 2
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Four door panel 1
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Panel comparison

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Location: Hampstead Maryland
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PostPosted: Tue Jul 20, 2021 10:28 pm
Cut the rusted panel out behind pass side rear wheel. Started to test fit the donor panel that was cut off of the four door. Donor panel had rusted area along rear flange I cut out will need to butt weld new metal in that area. Also need to weld holes shut where I drilled spot welds out. Still need to do more cutting along top and front edge where patch will be welded to panel on car.

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Cut off rusted panel
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Rusted panel removed
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Panel test fit 1
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Panel test fit 2
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