Rear corner quarter panels are difficult to fabricate and these were no exception. This side Is slightly different to the near side as the arch is longer and houses the fuel filler pipes. Daihatsu bolted a plastic splash guard in which had limited success .
The inner quarter panel wasn't rotten but pitted and I decided to replace some of it. The outer panel was rotten and more of that was cut away. This area is within 30cm of a body mount so in a prescribed area and so any rot is an instant fail. I got away with it the last couple of years by making the area not visible - they cant test what they cant see. Nothing is allowed to be removed by a mot tester.
As with the near side this panel curved in three directions. I thought sod that and redesigned it to curve in two directions. In fact I have redesigned this back corner and made the curved section of arch continuous from front to back therefore shutting off the filler pipe part with steel rather than a crappy bolted on plastic splash guard. Whilst keeping the wheel spray out it will make connecting the pipework much harder so I decided to make the filler pipes accessible from inside the car with a bolt on panel. More of that later.
Firstly made a small straight vertical piece at the bottom where the inner and outer quarter panels join. Clamped to a length of aluminium bar to get it straight.
For the other side I put the arch in and made the quarter panels to fill the hole. This time I have done them first and made them bigger than required so they can be cut down for the join to the curved arch.
This next one shows better the bends I had to put in .
From inside the vehicle. The back part of the inner arch will be removable for access from inside.
Plenty more to do but inching closer