There's a hole in my quarter panel!

I also found a bit of body damage on the passenger side. I guess I got a bit too close to a rock at one point.

So, this year I finally got around to tackling the repair. Yes, I know a lot of people cut the quarter panel and then fold it up, but I'm not most people. So, here's what I did to fix it.

First, I cut out the rusted panels.

Then I noticed the driver side was rusted worse so I cut some more rust out and formed/welded some scrap sheet metal.

Here the scrap was welded in. Close enough.

I painted the inside with POR15 Rust Prevention and their Top Coat and then sealed the seams.

I bought some replacement lower quarter panels from Raybuck Auto Body Parts and cut them to size.

The replacement body panels were flanged and held in place to be welded.

The replacement body panel has been welded and ground down.

I opted not to add body filler to smooth out the panel because I planned on installing some armor. So, I painted the lower quarter panels and drilled the holes for the well-nuts that were included with the Dirt Bound Lower Quarter Panel Armor.

I then ran into two problems. One is that I drilled the well-nut holes one size too large for the well nuts and the other is one of the bottom well nuts would not fully sit in the hole because the body behind it was in the way. So I scrapped the DB-design and welded some stainless nuts and washers to the body on the inside.

Once the outside panels were repainted and ready, I applied the POR15 and seam sealer treatment to the inside. Once that dried, I also top coated the inside with some refrigerator epoxy paint because it's hard and super slippery. I also added an additional drainage hole where dirt and water typically sits.

Attach the armor to the body, trim the Bushwacker flares, and call it done. Time will tell how long my "fix" will last.