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I admire your perseverance in restoring this Element. Now is a good time to be doing this kind of work if it isn't too cold and damp to complete it and stop the patches from rusting.

btw, Did you buy it E used?
 

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2008 EX AT
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126 Posts
Discussion Starter #23 (Edited)
Thanks so much guys! I’ve had this E for about five years and the body is solid except for those pesky lower rear doors. And now’s the time due to the lockdowns.

Patch panel initially Mig welded in place. I spot welded it continuously keeping the warpage at bay by cooling with a damp rag and compressed air.
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0FD621F7-D224-4142-B224-4B423FBFEE5C.jpeg Then grinding with a flap disc...
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A4FC9DE3-321B-456A-B9E5-820C88371B17.jpeg And then a skim coat of beloved Bondo, and a high build primer..
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F2E80DF3-4638-4EB0-85A9-294E8B15CFFB.jpeg
 

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2008 EX AT
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126 Posts
Discussion Starter #24
The passenger door has now been painted, wet sanded, buffed, and installed. This door was much more work as it had more rust in the lower sections both inside and out. I did alot better mig butt welding the sheet metal by keeping the voltage at minimum but turning up the wire feed speed higher. I also angled the welding nozzle a bit more for the spot welds.
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E7124E91-9047-4669-A508-4C9CDC0EEE3A.jpeg What I could have done better was taking care grinding the welds. My grinder drifted above the door’s lower crease, chowed the door crease a bit, and forced me to paint above the crease. Paint matching at a crease is much easier than mid panel which is a bitch. And the new paint is a bit darker as a result. But no more lower rear door rust so I’m glad of that!

Costs for this project:
Used driver’s side rear door $75.00
Sheet metal $15.00
Bondo and glazing putty $15.00
Sandpaper $20.00
Primer, finish paint, clearcoat $50.00

total $175.00

HF Titanium Mig 140 welder was $399.00 but I bought it for other projects too. A medium bottle of 75/25 shielding gas was $65.00.

I put in alot of hours with welding practice as well. It’s a wrap!
 
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