Take a look at these pics and let me know if you think this area is repairable or if I should replace the fender. The front is not even bonded as you can see in the pics. I don't want to waste any time on it if it is a lost cause.

 

I'd be tempted to replace the fender, especially if the rest of it has been over sanded (soft beauty lines, wheel arch etc).

 

So what is the procedure for replacing it? I knew I should have waited about glassing the seam but easier to fix now that later.

 

Take your angle grinder and grind down the fender until you get to the bonding adhesive and the fender falls off. This way the new fender should fit just about perfectly since you leave most the old adhesive in place. Just grind off 1/8-3/16 of the adhesive before fitting the new fender.

You can screw the new fender in place against the upper bonding strip while the adhesive sets. Be sure to place the screws right at the edge. After the adhesive has set, remove the screws and grind down the edge to remove the screw holes and glass the seam. Leave the back edge a little long until after it is bonded in place and finalize the door gap with everything in place.

 

So who offers the best fitting reproduction fenders? I seem to remember someone who is not a "vendor" who I have read others mention and he doesn't have a website. All the ones I have checked out online seem to be around the same price. Who do you reccomend for body panels?

 

If I was going to attempt to fix this area, what would I need to do? I am guessing I will need to start on the backside of the fender and lay in some fiberglass mat/cloth and try to get it to form to the shape that I need and then lay glass on the other side once it has set up.

 

Probably have a boat repair - fiberglass expert - in the area if you are near the water. Might check with them. Bet the boat repair business is a little slow given the economics now. Just a thought. Maybe you can get one of their glass guru's to moonlight. My boat guy works with me on the glass if I run into snags or have a tough shape or technical problem.

Often a big mistake us rookies make is to over build it. Fiberglass repair/layup isn't rocket science but there are some things that are critical - like getting all the air out and making sure that the resin is mixed properly or it will "kick" before you are ready or if not enough catalyst won't kick for a very long time. I believe youre idea to start with the rear to get the correct general shape is sound. The FSM on the C4 has a section about body repair, don't know about the C3 book. You might also check with a big box bookstore and see if they have a Boat repair/fiberglass repair book - generally lots of tips in those to keep you from learning the hard way. For fixing flexible parts (like the C4 bumpers), I recommend 3M Automix 5895. It's an epoxy that is easy to work with, shape and sand.

Consider pulliing a pattern off the opposite panel and reversing it to get a pattern for the proper shape. For the patterns, find a material (like a heavy plastic or vinyl) that you caan cut to shape and "back" the repair with while you lay the glass on top of it. Get some "mold release" to spray on the pattern so it will release from the new glass rather than bond to it. Check with your local body shop or auto paint supply for what to use.

And, from the looks of it, I wouldn't be inclined to wholesale replace the panel unless I could find one awfully cheap and pretty close to boltup and paint.

just some thoughts. Good Luck.

 

Of the various panels I've seen, Corvette Image was by far the best.

If you do want to fix it, the way I'd go about it would be to first grind the edge back and make sure I have a good foundation. This will mean your hole will get larger... Then build a backing surface (basically a mold) that slides behind the panel and you will lay your resin/mat onto.

 

no way i would replace a fender over that damage . clean it up, use some sprayfoam on the back and repair it . when done you can dig out the sprayfoam. but fit everything first.

 

What is sprayfoam and where do you get it? I am guessing I would need to mask off the outer side of the repair area to the shape I needed and then use the sprayfoam.

 

clean the back and make your mold from aluminum tape. the put a little spray foam on it for support while you do the repair. when done you can peel the tape and foam out.

 

so let me make sure I am following you correct on this porchdog. I want to use the tape on the backside of the fender and spray the foam on the tape for a little extra support and lay the glass on the outer part of the fender?

Now let me ask this, what if I taped off the outer part of the fender and then laid mat/resin along inside of fender and clamp everthing into place and let dry and then work the outer part of the fender with glass? would this make the area too rigid and easier to crack? Not questioning your method but wanted to know how the differences in repair would effect the finished product.

By the way, when you mention aluminum tape, what are talking about? is it the hvac tape that you can buy at lowe's and other places like that? I really appreciate all the help.

 

it's not the same tape. it is sold for doing diy auto repairs it is a little thicker than duct tape. i use it for a background and the foam for support. if i can get to the backside i will make a patch of woven and work on it.

 

I got what you are saying porchdog. If you will, take a look at my post on here "best fix for this" and let me know what you think. thanks