Expert: William Forster - 7/22/2006

Question
I have an 88 BMW 325 convertible.  The bottom of the right front fender is badly rusted (area between wheel and door).   I have been told to cut out the rust and repair with sheet metal (easier then replacing fender, painting, etc).  Would you agree?

If so, I have a couple of questions:

1.  The car is white & has a 6 inch black trim on bottom coated with textured rust protection.  I have to cut off bottom 2 inches of fender and replace with sheet metal.  How to I finish the repair area – can’t find any paint/coating products that have the same texture.

2.  Just picked up mig welding last year (self-taught).  Welded interior sheet metal on friend’s car – solid welds but very ugly.  I believe I can do fender fix because textured rust protection and a lot of grinding will cover ugly weld.  Do you have any tips/helpful hints?  Am I getting in over my head?

Let me know.
Thanks,  

Answer
If you get off replacing only the lower 2 inches of fender, you will be VERY lucky. Figure on replacing the lower 4 inches, minimum. You will absolutely need to use filler on the patch repair, texture coat won't hide much. The sheet metal will warp and distort with heat, I don't care if you're the best welder on earth. To get gravel guard, you need to go to Napa or Car quest, or anywhere that sells professional car paint. You will need to purchase a special gun to apply it, commonly called a U-Pol gun. They are very cheap to buy, however. Patches are difficult to make, so take yor time, and have it formed as close to the shape of the origional panel as possible before attempting welding. You may be in over your head, in my professional opinion, unless the car isn't much to look at. If it's in great shape, have the repair professionally done. Expect to pay 350-500 dollars, depending upon the severity of the rust. Bill