Started on the rot repair on the wagon, decided to tackle the worst panel first.

I copied the more intact passenger quarter onto some paper, transferred that to some 3/4" plywood, cut two out, and used those to hammerform a new patch panel.

Then I hacked off the old “repair” and bondo, and trimmed it up to fit the new panel.


Here is a tip from the prior owner, when repairing rust, don’t actually cut away all the rust, or use any sort of rust inhibiting paint before slathering on the bondo.


I’m impressed with the fit I was able to get, given I’ve never made a patch panel this way before.

Now I just need to fabricate the inner structure & the rear where the bumper filler mounts, and I an start welding this all together.