Wheel arch repair on a Ford Falcon XB Coupe. The reason for this repair was that the wheel arch was previously made 30mm higher up than the opposite side and was only discovered by the owner when putting the car back together and sitting the wheels on. In doing so I unearthed a disgusting amount of body filler and poor workmanship, so I templated the arch profile and made tooling for the Pullmax to recreate the shape, extended the supplied arch whilst adding shape and putting in the transitioning bodylines that meet into the lower quarters.
The quarter had to come outwards 15mm and the inner arch section was also remade to suit, then trimming and welding the flange to the outer skin for wheel clearance and to match the opposite side.
Overall, I'm quite happy with how the repair came out, but as always there is lots of room for improvement. A second pair of hands would have sped up the final fitting and made life easier and I also would have preferred to have welded a section like this in with the entire quarter off the car but unfortunately it wasn't a possibility here. A real shame there are shops out there charging $65K doing this kind of work and getting away with it because people can't see under the shiny paint. Should be a real eye opener for some people that if the shop you are using isn't showing you any pictures in the metal stage before filler and primer, the alarm bells should be ringing. There is a big difference between a 2mm skim of filler edge to edge to really enhance bodylines and get the car laser straight, than absolutely loading it on 8-12mm thick like this and using it on openings and edges.
Cheers for taking the time to watch!