Trunk & Rear Quarter Rust Repair - 1965 Dart Convertible

Time to fix the rust on the front corner of my donor trunk extension. If Jesse James can beat a flat piece of metal into a motorcycle gas tank, then how hard can this be?

I got this makeup case at the Salvation Army for a couple dollars and filled it with sand. Poor man's shot bag!

The plastic hammer with the white head came from Harbor Freight and worked really well for stretching the metal without marring the surface.

The trick with the weep relief is to form that first while the piece is still flat before bending the bottom flange. In my first attempt, I bent the flange first and then I couldn't form the weep. Threw that piece away.

I made cuts along the wheel lip to make it easier to form the curve. I also ended up making a relief cut along the bottom to raise the bottom flange up a bit. These got welded at the end.

I did some grinding and dolly work on the beads. They're not undetectable yet, but after media blast, a teaspoon of bondo should fix that.

My flanges are bigger than they need to be. I'll trim them with the grinder after it's welded to the quarter panel.