Body Repair Decissions

It is time to address my body repair. I have the rear wheel well panels and the front side panels. but attaching them is the issue. The videos I have watched use several methods. The easiest would be the special epoxy method, but the videos usually cut most of the under laying metal away and only leave a one or two inch overlap for adhesion. I have a lot of good solid metal underneath and would like to keep it. But I want to insure something completely seals the two surfaces so moisture doesn't get trapped inside. I could ruff up the existing paint, not enough to expose the metal underneath but enough to get better adhesion.

Has anyone done this? Ideas or pointers maybe, .......

 

Rough and nasty, but I use aluminized tar roof coating for preserving body metal, especially in potential water traps. Works very well if you aren't concerned about beauty.

 

Pics? Guessing this is on a CJ? Home-made panels or store-bought?
This seems to be a popular alternative to molten metal repair:
https://www.3m.com/3M/en_US/p/d/b40066467/

 

Panels are purchased, I also have heavy gauge Rugged Ridge rear corners. The corners I figure will be bolted on, and I have to cut holes to weld in my tail light buckets.

But it is the side panels I am looking at.



The Gas fill is moving to just in front of, and level with, the tail light.

 

That is a tough decision. I suppose it has a lot to do with what you want the finished product to be. I have not seen those
panels before. They appear to be of a type to bond over an existing panel.

 

What width is the top rail on the new panel?

 

The top rail that this is going over is .870

The inside dims of the panel is .910
and the measurement across the top is , ....... 1 inch

the thickness of the panel is .040, so slightly thinner than 19awg. So definitely a glue on panel, just got to figure how to do it so liquid can't get inside.



p.s. .... I like to weld over gas cans, ..... makes life exciting, ..... don't ya think

 

laser welder...