Details:
What I started with is pretty obvious from the first pic. A lot of seam sealer was used in this area. This sealer cracked and let water sit on the metal, rotting it away. The first step is in the first pic below. I fabricated three seperate pieces from sheet metal to repair the upper corner (see second pic). One piece for the rear deck filler, one for the upper trunk gutter corner, and one for the surface of the quarter panel. I welded those pieces in. Then, I had to fabricate another three pieces to handle the side gutter and quarter rot. One piece was to repair the corner where the quarter metal folds over to the gutter. The other two pieces replaced the metal pieces on the side gutter that had rotted away on the quarter and gutter pieces.
The hardest part was creating the corner pieces with all of the curves and flanges. I did them in solid pieces, so even pieces that had several 90 degree lips were done with one piece of metal. I used a shrinker/stretcher and a 30" bench-top brake.
All of the pieces were butt-welded in and or spot-welded (in places where spot welds were originally used). I then ground down all of the welds on the top and bottom. I'll eventually smooth out some of the rough spots with all-metal and all of the seams will get seam sealed, just like the factory did.
Now, on to the next side...
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