WELP finally got around to the driver's side dogleg today, and I have to say that it's been least fun part of this project so far. That said, it's done, and I lived to tell the tale.
The dogleg was rusted in various spots, as was the inner fender lip, which I also had to rebuild. Had to do quite a bit of cutting to even see what I was dealing with:
Once I had the inner fender lip rebuilt (forgot to take a pic), I took the outer dogleg that I'd built previously, and cut it down to size:
Then I grabbed the panel epoxy, and glued the patch in place, again using sheet metal screws to help clamp it in place while there glue cures (overnight):
My next step was to grind the top profile of the patch piece to match that of the existing sheet metal, and then weld them together. I also made some smaller patch pieces to replace the rusted areas I'd cut out earlier. Again, I forgot to take photos (was rushing because it was supposed to rain), but here's the end result:
One of the trickier parts was forming the little "lip" where the outer dogleg meets the existing metal - especially given the weird compound curves etc that are involved.
Anyway, again, it's not perfect, but there's solid steel where once there was only rust. Good for another hundred thousand.
Still need to rebuild the very lowest part of the dogleg, where it meets the rocker. There a lot of work needed in that area, so I think I might hold off on that for a bit, and start working on the passenger side rear fender and quarter panel.
