'95 Civic EX 2Dr - rust repair repaint project

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PostPosted: Fri Jun 11, 2021 2:12 pm
Doing some rust repair and repaint on my son's Civic EX 2 dr. This project started spring 2021. The typical rust in the quarter panel situation. He bought the car around 6 or so years back for cheap and used it for a daily driver. It has been parked at my house a few years now awaiting body/paint. This spring it got a 2.4L Acura engine and Accord 5 spd swap dyno tuned ect very strong runner. The car will go back to its original color white when done and retain a stock appearance look.

The car does appear to have original paint except pass side quarter panel. So we do not believe we will be dealing with old bondo accident damage unknowns under the paint. Overall body not too many dents car is pretty straight for the most part.

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On lift


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rust drive side


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pass side
Last edited by 69cuda340s on Fri Jun 11, 2021 3:52 pm, edited 4 times in total.

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PostPosted: Fri Jun 11, 2021 2:21 pm
Started on driver side quarter panel. Patch panels are only available for 3 door hatch backs. So the rear section of the patch had to be cut off. Tried to line patch with gas door opening but that did not work and I ended up cutting lower rear of patch too short in order to get patch aligned with bumper. So now I get the pleasure of adding metal since too much was cut off.

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patch 1


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patch 2

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PostPosted: Fri Jun 11, 2021 2:28 pm
So I worked on fitting quarter panel to patch and then focused on getting that metal added back where patch meets bumper. Took a piece of 18 guage and cut bent hammed to shape. It has some odd curves due to character line that spans quarter panel to bumper cover.

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patch 1


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patch 2

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PostPosted: Fri Jun 11, 2021 2:33 pm
Welded section by bumper to patch panel. Welds are not fully grinded at this point. I usually like to go take a break come back fresh and do the final flattening.

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welded 1


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welded 2

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PostPosted: Fri Jun 11, 2021 2:37 pm
The U section down low on the rocker was too short so had to cut, create a big gap, and then jump the gap with weld. The lower front section above rocker had to have the curve put into it to match curve on lower quarter panel. Also needed square fastener hole cut into rocker area of patch since this can not be done once patch it on the car.

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lower rocker area
Last edited by 69cuda340s on Fri Jun 11, 2021 3:55 pm, edited 1 time in total.

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PostPosted: Fri Jun 11, 2021 2:46 pm
Spent more time tweaking patch fitment. I learned from previous projects the better the patch fit, the more precise the gap between patch and quarter, the less work later to weld and finish. So this time around I want to do more up front work and take more time now so less work later and higher quality repair.

Added screws to hold patch in place since support braces are behind patch preventing butt weld clamps from being used. At this point the patch fitment prep is complete. Inside the quarter panel is a holding fixture I fabbed up which mounts through the body side molding holes. This makes it easy to locate patch consistently as patch is repeatedly removed replaced during fitment process.

Note that NO bondo or accident damage has been found in the quarter panel which is nice unlike the last project I did.

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patch 1


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patch 2

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PostPosted: Fri Jun 11, 2021 3:00 pm
So apparently water sat in area behind rear wheel and under bumper cover. We knew rust was there but it turned out to be far more then expected.

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rust 1


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rust 2

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PostPosted: Fri Jun 11, 2021 3:08 pm
So cut out rusted area and more had to be cut then expected in order to get back to clean metal. A section of trunk drop down and brace inside trunk had to be cut out and patched due to rust. Sort of awkward area to weld/grind not easy sitting on the floor but got it nice and solid and no rust in inner structure now.

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cut out


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patch 1


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patch 2


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patch 3

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PostPosted: Fri Jun 11, 2021 3:19 pm
So I hammered, bent in vice, brute forced a two piece patch in shape to fill the large opening. I do not have metal break or correct tools for this type of work so sort of muscle brute strength determination was applied. No gracefulness here just get it done. Old cardboard cereal box worked great for size and shape templates.

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patch 1


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patch 2


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patch 3

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PostPosted: Fri Jun 11, 2021 3:29 pm
The upper top patch was formed to match the little bump/curve of the original panel and then welded into place. Lower section wired wheeled down. Bottom patch will be epoxy primed and panel bonded in at a later time. The seam between top and bottom patch will be butt welded. Some trimming along bottom needs to be done so that it matches bottom of trunk drop down area.

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patch 1


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patch 2
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