So I decide I'm going to paint flames on the 544 and put it in the 4th of July parade. The body/paint guy convinces me to do a "down-n-dirty" paint job before painting flames because the body and paint are awful on this car.

Open the can-o-worms.

The fender welt is 40 years old and has 2 respray coats on it so off come the fenders. The right front fender has only one bolt holding it on in back and the left is held on with a piece of channel riveted on the back and a piece of plumbers tape on the top. Both rear fenders come off but I break off a few of the captured nuts in the process. Also found a piece of Bondo the size of a beer can holding the whole frame rail together on the drivers side under the door.

Home Depot.. Lincoln wire feed welder.. $200... and I start practicing on the car. 8 hours of welding time and I'm getting better but still suck. I weld in new nuts into the steel behind the fenders but the huge rust spot in the driver's door/frame rail needs a pro.

I go out to the parts car with a sawzall and cringe as I cut a huge section out of it. The bodyman calls his welder friend and tells him how he should come over and participate in this "fun project". Bodyman cuts everything down, overlaps all the joints and the welder goes to work. This guy is good and sticks everything together all pretty with actual beads and everything in about an hour.

I get to practice welding on 3/4" wide rusted out strips on the body over rear fenders. I can sometimes get a bead 1" long but usually get a bunch of pops and crackles and some spots that might be stuck together .. or might not. They're just fenders anyway right? If they fall off I can always try again.

Well here we are 4 days till parade day. I've been working 24 hours out of the last 48 trying to get this project together. One fender is on, nine new fender nuts have been welded into place, the hood, doors and deck lid are now straight and in primer. We're supposed to shoot paint on Tuesday and paint flames on Thursday, Wednesday is my day for bolting everything back on, fitting fender welt, etc. If this gets done. I'll definitely submit some pictures. Until then here are some rust repair pictures for your amusement

rust


rust repair

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Bob W.
15 Volvos ('58-'91)
445-544-122-240-740