A - Pillar Repair DIY

[Silentdub]

A Pillar Repair.

This side of the car wasn't nearly as bad as the other. Before you attempt this repair, understand that there is more than 1 piece of sheet metal in this area of the car. The outer sheet metal is what makes the car look smooth and pretty, however under the top piece of sheet metal is another piece right below.

In my case, the one side just needed the top layer of sheet metal replaced, the other side needed both pieces replaced. Lower replacement pieces can be purchased, however, I had a donor car and the one side required more metal than what is available for purchase anyway.

Keep in mind, that I did NOT replace the drip rail portion since I was getting rid of that anyway. The same DIY would apply however, you could replace the section of drip rail, or if it is not affected, you could cut around it and just replace the damaged section.


The damage on this side:



Doesn't look too bad, but it has been patched before, so there is more than meets the eye.


The donor piece that I cut:



After I brushed up the surface a little:



A close up shot, yes that is a light bulb that I found in there.







I took the donor piece, laid it out on top and basically used primer to mark the area to be cut out. I would normally cut out the damage area then cut the donor piece to match, but I figured fuck it, no big deal, so I replaced 3 inches instead of 2. No big deal. It would also cover any damage from under it that I couldn't see.





Notice the two pieces of sheet metal.

There is the outter shell and inner shell.





Obviously, I replaced the inner shell first.
There is no need for this to look pretty, just make it strong.



Some of my first nasty looking welds, like I said, no need to look pretty.






After you finish the inner piece, be sure to coat it with "weldable primer" as well as any anti rust treatment / sealer before you close it up.



When welding in the new piece, it is important to know that you need to be gentle not to use too much heat, as the metal will shrink when it cools and cause it to look like shit.

I pictured a little ball peen hammer in the picture, as you make one or two tack welds, the metal will twist and turn a little, use some taps of the hammer to keep it straight and flush with the surface.

Place tack welds around the edges about every inch or so. Keep tapping the sheet metal back in place and keep putting down some welds.





Grind it down and you are good to go.

[Silentdub]

I found some other pics from the other side of the car.
see below:

[Silentdub]

1 more pic for reference