My '73 Roundie Revival [BMW 2002]

[IronFreak]

Truly inspiring work man! great job, from someone that's been welding a long time, you are progressing ridiculously fast!! Love the fact that your had some big balls and said screw it and jumped in. way cool!

[pacmanE30]

beautiful work on saving that fender man. your methods are getting better and better as you progress!

[CubbyChowder]

Good work on saving the panel.8)

Thank you!

Dude, I'm so motivated watching your welding skills progress as this build thread moves on. Awesome work! Makes me want to pick up a welder and just start going at it! Did you receive any welding training or metal-working tips prior to starting this project?

Thanks man! I had very little welding experience before this project started. I mainly researched online until I felt like I knew what I needed and certain techniques. It's very easy to learn and get the hang of. I would definitely recommend using shielding gas with a MIG (like 75/25 argon/Co2) instead of flux core wire. You can weld way thinner metal that way and the welds are way cleaner. I say just find a decent machine and go for it, it's a great investment and lots of fun.

Nice patch job! Most would of replaced the fender! I like! Why'd you opt to make the patch in sections rather than one piece?

Thanks! I did that because I would've had to have been extremely precise bending one piece of metal to the same shape as the body. Doing it in 3 sections just made it easier for me to match the body lines.

[lostininglewood]

Nice patch job! Most would of replaced the fender! I like! Why'd you opt to make the patch in sections rather than one piece?

[Cha Ching]

Dude, I'm so motivated watching your welding skills progress as this build thread moves on. Awesome work! Makes me want to pick up a welder and just start going at it! Did you receive any welding training or metal-working tips prior to starting this project?

[rav320uk]

Good work on saving the panel.8)

[CubbyChowder]

The passenger's side front fender had a rusty spot where it rotted through:



Took it down to bare metal to see how far it went:



Cut it out. I ended up having to cut out a portion of the outer fender skin but also a portion of the inner panel where it mounts to the body:



I'll try to explain as good as I can, but as you can see in this picture, the outer fender skin wrapped around another piece of sheet metal which turns into the mounting area for the fender:



I wanted to replicate that so it all looked normal, so I took a flat piece of sheet metal and bent the end over another sheet of metal, making it 3 layers thick, just like the original piece:



This also gave it a nice "rounded off" look, like the rest of that area on the fender has:



Since there was quite a bit of contour in the area that I was replacing, I decided it was best to do it in three different sections. First bit tacked in:




Second bit:



And third:




Once they were all tacked in and everything looked good, I welded the rest up:




Smoothed it all out:




When looking at it straight on, you'll notice that the top portion flares out to the left more than the bottom section and the small middle section ties them together. The original body lines do the same thing, and I wanted it to be as close as possible, and it looks basically identical to my other fender in that area, which I'm stoked on. I'm happy with how it turned out on my first go:



After that was done, I had to replace the section that mounts the fender to the body, so I cut this out:



Which goes here:



I also cut out the rusty section next to that and cut out a piece of metal to replace it. I then tacked everything in from behind. I still need to prep and paint that area so it looks a little ugly right now:



Thursday I begin my final MK1 fender flare!

[CubbyChowder]

thanks for the kind words everyone!

Looking good =)

I might have euro 2002 bumpers with the trim for sale if you want them. Still pondering over keeping the 2002 or selling and getting my dream 2800 that is local to me.

I might be interested in the rear bumper depending on price. Can you PM me with more details please?

also are you using adapters, 5-lug, or fill and drill for the e38 weaves?

I'm using adapters, check out my build thread in my sig for full details

[mohamed...]

also are you using adapters, 5-lug, or fill and drill for the e38 weaves?

[F34R]

Looking good =)

I might have euro 2002 bumpers with the trim for sale if you want them. Still pondering over keeping the 2002 or selling and getting my dream 2800 that is local to me.

[mohamed...]

You are my hero. I would always see you sig but never clicked it because i knew i would be very jealous. Then today i saw a 2002 on the way home and i thought it would be fun to do my very first build so i found your thread. you have done amazing work, keep it up! i cant wait to see the finished product. i am determined to find a project to start working on before im 16. then i will have my dd e30 and a fun project! cant wait to see your finished product.

[BamaE30]

Your work is very nice inspiring me to start my 2002 this summer.

[pandaboo911]

Yes, that's much nicer than my cramped ass garage filled with spiders..

Git er done

[Scallywagon]

Stick to it Cub, always worth the struggle!

[mtlbloodshot]

I cant wait to see this done, Keep it up!!!