Welding the rear quarter wheel arch

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Wheel arches mania

Started welding on the rear right wheel arch today, I hope to finish it tomorrow. It is hard to shape the metal to the smooth round shape of the wheel arch. Much easier if I had a replacement part, but these parts are rare and expensive since it’s a coupe and the rear section differs from the station wagon and sedan models. A part from an old wreck are hard to come by and would had the same rust problem in 99% of the cases. So better off doing it the hard way.

rusted right rear wheel arch
Rusted right rear wheel arch

Obviously I had to make a huge hole and remove the old crappy metal.

Welding metal into the wheel arch
Making some wheel arch

Cutting panels and shaping it is an art, and I’m not an artist, just a simple engineer.

Welding wheel arch
Welding first seam

Welding along the seam needs patience, the metal here is very thin.

Welding wheel arch
Welding continues

Also have to make the inner weld which I didn’t take pictures of.

Welding wheel arch
Adding lower part

This last part is a tricky one though. How will I be able to replicate the smooth shape?

Welding inner wheel arch
Welding the inner sides

Making the car water proof once again.

Wheel arch welded tight
Final polish before paint

Welding done! Think I have swung the hammer more times today than any other day in my life! An exact reshape of the arch was not possible from my side. Will need some filler to make up the last touches.

Wheel arch painted
Wheel arch painted but not done

Painting the metal and then applying filler.

Wheel arch finishing touches
Finishing the touches with some body filler to get the smooth shape, harder than I thought. Used a filler that is easy to sand.

I was quite pleased with the result, but is not as perfect as a replacement arch, will look into that in the future…maybe. So fast forward in time, here is the end result. Not bad for an amateur like myself!

Result after welding wheel arch
Wheel arch after painting

You can see the slight difference in color where the old and the new paint meet. I also think the shape of the arch is nice.

Author: robs

Passionate about older Mercedes Benz where driving, maintaining and learning new things is what keeps me doing this. Enjoying writing about cars and teaching others on the black arts of car maintenance. Have a major in space technology engineering and currently doing IT consulting for a living.

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