Yo FordER,
Welcome to the Zone!
We've been battling that wheel arch rust for a few years now too. The inner fender is spot welded to the outer 1/4 panel and this method causes all the 1/4 panel rust problems;
The usual practice is to cut out the entire 1/4 panel & weld in a new piece; or replace the wheel arch section.
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Quarter Panel Repair on an 85 by Chris B (Blue) at
http://web.archive.org/web/20041027164302/http://chrisb.users.superford.org/Projects/the_rear_quarters.html
Alternatively is to use body adhesives in lieu of welding.
Replacement w/adhesive in an 86 by Sixlitre (Malcolm H, Eddie Bauer) at
http://www.superford.org/registry/vehicles/detail.php?id=4970&s=19605#content]
Malcolm used an Astro Pneumatic 3/8\" Spot weld cutter.
Site is slow
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to save $ on a compl 1/4 panel, I bought the 1/4 panel patch panels. They are primed and of 18 gauge steel - exact fit around wheel well arch and packaged very well for shipping.
90-87-52-LH LH left hand (driver side) Upper Wheel Arch Area, that fits pickup or Bronco. $23.10 each
http://www.rustrepair.com/PANELS/FORD-BRONCO-REPAIR-PANELS.HTM
I ordered it on 6 JUN 2011 @ 1225 hours and received on 8 JUN 2011 !!! S & H cost for both from Cleveland, OH to NJ was around $12.00.
Fits from the horizontal crease below camper top down to wheel arches and around the arches, exact fit. Was able to weld w/no adjustments to it or the 1/4. Can be attached w/body adhesive or even PL Premium; Sixlitre has been experimenting w/PL Premium on some parts.
Of course, cut the rusted arch section out and inner panel. so you can inspect and clean higher up inside 1/4
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Patch Panel Installation, Jeff's Bronco Graveyard in a 94
Source: by R94BroncoXLT (Ryan) at
http://www.superford.org/registry/vehicles/detail.php?id=4853&s=21778#content
Site is slow
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Some have used LORD Fusor® 108B/109B metal bonding adhesive is specified for use by General Motors, Ford Motor Company and Nissan. It can be used for panel bonding,weld bonding and rivet bonding of properly prepared metals, including aluminum.
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MIG Welder, Lincoln Electric, Setting for Body Panels pic; "this is the perfect setting for sheet metal work---with 35 CFM of Ar/CO2; he shows slightly less than 2 and on E in the pic..."
Source: by mickaila
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Replacement w/adhesive w/parts list; including wheel house in a 90; Panel Adhesive, $26.00 a tube & Application Gun, $65.00 by wheelersautobody.com , etc.
Source: by Jason T (Broncomx, Two Face)
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Wheel Arch Fabrication, Fiberglass in an 86 (left click mouse & drag over to view narrative)
Source: by Matt J at TheBronco.com via
http://web.archive.org/web/20050306183552/http://www.thebronco.com/projects/pr0201.html
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AutoFab - Bronco/Ford truck/Ranger fiberglass fenders (& "Ashley style"), hoods, quarter panels, tailgate for 92-96; engine mounts for 80-96; 9" skid plates; 9" skid plate; pre-runner bumpers (92-96 Bronco/F150 w/skid plate; 89-91 w/out); Mastercraft racing seats; 80-96 Bronco/F150 4" front lifts for 16" wheel travel; Bronco/F150 rear lifts for 16" & 18" wheel travel
http://www.autofab.com
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McNeil Racing, Inc. & Perrys Fab n Fiber - 73-96 Bronco/Ford truck fiberglass fenders, hoods, quarter panels; one piece fiberglass front end for 80-96 Bronco, 73-79 Bronco Conversion to 96 Bronco, 92-96 off road & OEM style fiberglass & carbon fiber dashes with built-in center console (same as FiberwerX dashes)
http://www.mcneilracinginc.com
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For extended spot weld cutter life;
Rotabroach Stick Lubricant is specially formulated for use with Blair tools.
Increases tool life and cutting speed.
Apply directly to the tool before cutting. A waxy type lubricant that melts and provides lubrication to the cutting teeth.
or;
use a light machine oil, WD40, motor oil, etc... clean the area before installing new panel & painting etc.
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