BMW Wheel Dome Body Work Repair 1

Since the radiator/bumper/grill had been removed it was very easy to gain access to the motor compartment.  It was elected to make the sheet metal body work repairs within the motor compartment prior to installation of electrical components.  Penetrating rust was present on both wheel well domes around sheet metal screws in what initially appeared to be relatively small areas.   As is stated repeatedly in the literature, once observed "paint bubbles" are opened up, significant lateral rust damage can frequently be discovered.  That was the case in this repair.

Picture DSC01145 showing the right side rust on the wheel well dome prior to debridement.

Picture DSC01177 showing the intermediate stage of rust removal of the rust that was discovered under the "paint bubbles"

Picture DSC01247 showing the final prepared area ready for grafting.  The borders were made as straight as possible to facilitate the placement of the metal graft.

Picture DSC01213 showing the salvage yard donor 525iA BMW from which sheet metal was cut using a thin abrasive metal cutting wheel.  Since the donor location had a similar curvature as the destination location, it was expected that very little bending would be required for the graft.

Picture DSC01226 of the donor sheet metal.  The piece was placed behind the opening where the rust had been removed and the outline was traced with a pencil.  On the workbench an additional margin was added and the sheet metal trimmed with a cutoff wheel at the outer margin.  Paint was then removed with a wire wheel to yield the graft shown in picture DSC01232.

Picture DSC01232 showing the sheet metal graft prior to crimping a step margin into the metal.

Picture DSC01224 of an IR 114GQC Air Hammer connected to an S & G Tools pneumatic crimper attachment.

Picture DSC01225 showing a close up of the die portion of the crimper tool that will produce a step on the margin of the sheet metal graft.

Picture DSC01236 demonstrating the outline formed after the crimper tool was used to produce the step in the sheet metal graft.  About 2 minutes was required to produce the step, and then about 5 minutes was required to touch up the edges with a piece of metal bar stock and a hammer.

Picture DSC01237 demonstrating the insertion of the sheet metal graft into the prepared defect in the BMW wheel well dome area.  The graft will next be tack welded into place followed by welding of the entire circumference of the graft.