Rear quarter rust repair in progress...

[magicmike]

Removing the bumper as a unit is how I did it—"just" the four beam bolts and the side brackets. Were your flat brackets that the bumper cover to bumper beam nuts go through junk, too? Most of mine are garbage, so I'm replacing them with aluminum flat bar from the hardware store—nearly an exact match. I wonder if I can get replacement nuts for that at the dealership. For a reasonable price.

Well technically there are the 4 bolts that hold the bumper beam on, 1 nut and 1 bolt on each of the metal side brackets, a large 17mm with a phylips head bolt on the bottom front on each side, and a 10mm bolt if I'm not mistaken attaching to the fender at the top on each side.

As for making those side brackets out of alluminum I think you'll have some difficulty. What I mean is that where the bolt and nut are attatching to the body of the car are at a different pane than the slots for the clips. Also, it will be be tough welding nuts to the alluminum, unless you just tap a thread in there if its thick enough.

If you made it look something like this you would be ok.

____/````\_________/````\____

[evolutionmovement]

Not the side brackets—the more-or-less flat pieces the weird small thread/thin-headed 17mm bolts that hold the top and bottom rear of the cover to the beam go through. Forgot about the other bolts for the cover since my mounts there are rotted. It's like 1" wide, and variably a few feet long.

[Legacy Rally Guy]

Hows your stuff looking now?

The dealer here in Columbia, Missouri said that they've the body panels in, but it'd be very costly.. Just like how I needed a good turbo front bumper, but couldn't find one, and eventually broke down and bought a brand spanking new bumper from the dealer.

[SPUMONI_RT]

Those metal shrinking disc are a joke.

[kimokalihi]

Hows your stuff looking now?

The dealer here in Columbia, Missouri said that they've the body panels in, but it'd be very costly.. Just like how I needed a good turbo front bumper, but couldn't find one, and eventually broke down and bought a brand spanking new bumper from the dealer.

Holy! How much was the bumper?

[fishbone79]

Those metal shrinking disc are a joke.

The I think the ones you must be talking about definitely are (I've seen them, they are gimmicky). However, these are very different and worth their weight in gold for anyone who does filler-free body work. The classic/custom body shop pros use this guys' instead of traditional shrinking with torches, etc. I've been working with a real old timer for the past year learning how to do leaded panel body work - he says that thing has basically cut the work time in half.

I've gotten good enough with it now that I rarely even use a bumping hammer... I can pop out a deep creased oil-can with this shrinking disc and finish off with a pick and dolly. You basically just start by shrinking the highs around the edge where the metal has stretched, which usually pulls the center taut and pops the dent out. I despise bondo, and these are one of the easiest ways to avoid ever touching the stuff.

[Legacy Rally Guy]

Hows your stuff looking now?

The dealer here in Columbia, Missouri said that they've the body panels in, but it'd be very costly.. Just like how I needed a good turbo front bumper, but couldn't find one, and eventually broke down and bought a brand spanking new bumper from the dealer.

Holy! How much was the bumper?

um, I think around $230-$270 It's been about a year since I bought it.. lol Yeah, a bit pricey, but sooo shiny and new and perfect!

[smidge]

watching this thread with interest as i just found a crapload of rust in the rear drivers side (aussie spec) quarter panel from a dodgy repair

the repairs are supposed to be warrented for the lifetime of the vehicle so i'm going to try and find out who did them

otherwise, looks like i'm gonna be mr panel welder

[magicmike]

This thread is dead for the moment as its winter and I wont be starting back up again until the spring, if I even keep the car by then.