Trunk Lid Repair - No Welding

[tndave]

I got tired of trying to find a trunk lid replacement so I decided to take a crack at repairing it myself. The inside corners are rusted out bad with most of the metal gone. I can weld pretty well but sheet metal fabrication is not my thing especially the areas on my trunk lid that needed replacing. First I cleaned it up best as I could then mopped on the Por-15 to stop the rust. Then I got a can of "Great Stuff Insulating Foam Sealant", (the expandable stuff) and filled all the holes. The next day I shaved off the excess insulation and then applied fiberglass body filler. It's turning out better than I thought it would. Check out the pics and let me know what you think.

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[hotrodder]

Can't wait until it's finished. I may too end up trying to repair mine, but man it's in quite some bad shape.... But, with mine in the shape that it is, and what's missing, it's not going to be an easy task, and probably would be best to find a buddy with a TIG welder due to a MIG would probably shoot straight through sheet metal like this.... Anyway, looking good.

[tndave]

Your right, Tig is the way to go. I have a Mig and tried it with no success

[tndave]

More recent pics - sanded and epoxy primed

[Deleted]

Very very nice. Way to go. Nothing like plain old ingenuity.