I have decided that I have to do something about the rust on the rear wheelwells. Can't stand the unsightlyness of it any longer. I think that I am limited to the following four options:

1. Cut off the offensive rust and weld in new metal, sand and paint.
2. Cut off the offensive rust and install metal or plastic fender flairs.
3. Install new quarter panels and paint.
4. Get a new Bronco.

I can't sell the Beast, too much sweat and pain put into her and it took me forever to find a 92-96 with 5 speed, cc, and power options. I want to retain the stock look, so the fender flairs are out. That leaves cut and weld or new quarters. Cut and weld may not end up with stock-like look unless someone makes the metal pieces that can be welded in and have the right bends, etc already there. This leaves replacing the quarters.

The existing quarters are tack welded onto the rest of the vehicle. How are these tack welds taken off? Drilled out and the new quarters welded in place? Is this a mess to do? The black paint on the Beast is chalky and needs being redone, so I don't mind having to put new quarters on and painting. Just don't want to get into a job that quickly gets beyond my means.

Any thoughts?

 

[updated:LAST EDITED ON 27-Dec-02 AT 10:43 PM (EST)]There is a special bit that body shops use to break the spot welds on body panels, and you can get it here:
http://www.eastwoodcompany.com/cgi-bin/sgdynamo*****?HTNAME=default2.htm
Search for "Spotweld Cutter".

 

 

There is a place on here that sells the weld in peices: they also have the whole quarter, depending on the rust, you might need it all like i do, i am just going to put on new whole quarters, it is just drilling out the spot welds, or with the special tool, and just wel back in place, i have also heard of people using special adehesives to hold it on, check all the posts, there is a site posted that shows how to do it, it is a big job, here is that site


http://autostyles.com/bpbronco8096.htm

 

Ooh, I forgot! Another option is to swap the body out for a nice low-mileage one that's never been wrecked/repaired/modified...
http://www.webphotos.com/list_photos.asp?mi=3&smi=2&a=95012