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ZachRoyGarage

Ford Mustang

7
Builds
32
Knowledge
59
Parts
56
Tools

Builds

Knowledge

How much extra clearance will custom fender wells give me?How much extra tire/wheel clearance can I expect?How difficult is this for someone with limited metalworking experience?How do I prevent warping when welding thin sheet metal?What finish work is needed after welding the new wells?What materials and thickness should I use for the tubs?What gauge of steel should I use for custom fender wells?How do I prevent rust where I cut and weld?How much wheel/tire clearance should I leave when shaping the fender well?How long does a project like this typically take?What wheel/tire sizes can this modification accommodate?How much wheel/tire clearance gain can I expect?How do you prevent warping when welding large panels?What welding technique is recommended?What safety precautions are important?Will cutting and welding the inner fender cause rust problems?Will cutting the inner fender affect structural integrity?Do I need any special tools to make custom fender wells?Do I have to weld the new wheelwell panels, or can I bolt or rivet them?Do I need a welder to do this, or can I rivet the tubs in?Will this change how the suspension or alignment behaves?Do I need to remove the fender to make custom wheelwells?Will modifying the inner fender affect vehicle safety or inspection?Do I need to weld the tubs in or can I use rivets?Do I need to weld the new fender wells, or can I rivet/bolt them?Do I need to use preformed tubs or can I fabricate from sheet metal?Will this modification affect vehicle legality or safety?Will cutting the fender wells affect structural integrity?Do I need a welder or can I use rivets?How should I protect the new metal from rust?How much clearance should I allow for larger wheels/tires?How do I protect the repaired area from rust and road debris?
Parts (53)
Sheet metal (mild steel) - 18-20 gauge
Universal inner fender liner / splash shield
Seam sealer (automotive)
Seam sealer
Pop rivets / sheet metal screws
MIG welding wire / shielding gas (consumables)
Body filler (Bondo or similar)
Sheet steel (20-18 gauge) for wheel tubs and patches
Aftermarket wheel tubs / inner fender tubs (or pre-formed tub panels)
MIG welding wire (ER70S-6, 0.030")
MIG welding wire (ER70S-6, 0.030-0.035" spool)
Grinding / flap discs (pack)
18 gauge cold-rolled steel sheet (for tubs)
Preformed wheel tubs (alternative)
Seam sealer / panel adhesive
Weld-through primer / zinc-rich primer
Automotive body filler (Bondo or equivalent)
Self-tapping screws / rivets & nutserts (fasteners)
Body filler (Bondo or equivalent)
Primer (etching/epoxy primer)
Rivets / self-tapping sheet metal screws
MIG welding wire
Primer (self-etch or epoxy)
18 gauge mild steel sheet (or equivalent sheetmetal)
Pop rivets / rivet nuts
Wheel tub / inner fender panel (replacement or prefabricated kit option)
Shielding gas (MIG mix)
Body filler (Bondo) / finishing materials
Topcoat / bedliner / underbody coating
Rust inhibitor / etch primer (optional)
Body filler (small tub)
MIG weld wire (flux core/alloy appropriate for mild steel)
Mild steel sheet (approx. 18ga)
Aftermarket fender well liners / splash shield (trim-to-fit)
Pop rivets (assortment)
Automotive seam sealer (tube)
Primer / rattle-can (epoxy or etch primer)
Underbody coating / rustproof spray
18-gauge mild steel sheet
Weld-through primerEastwood
Epoxy primer (quart)
Body filler (Bondo)Bondo
Plastic fender liner / trim material
Grinder / flap discs / cutoff wheels (consumables)
Seam sealer (tube)
MIG welding wire (ER70S-6 spool)
Grinding/flap discs (pack)
Sheet steel (18 ga / 1/16")
Preformed inner fender / wheelwell panel (replacement or donor)
Plastic fender liner / wheelwell liner
Pop rivets / fasteners (kit)
Self-tapping screws / hardware
Primer and paint (rattle cans or small kit)