How to Repair a Rusted Wheel Arch

Rear wheel arch rot is common in a lot of vehicles, and especially in pickup trucks. The rear tires spray water around, and road dirt, grime, and salt build up in the area between the inner and outer panels. This grime buildup can hold moisture which will eventually start to corrode the panels from the inside out. In pickups it's even worse because manufacturers spray a "sound deadening" material into this area. This material acts like a sponge that holds moisture. In a fairly short amount of time, that moisture will rust through the outer wheel arch of your truck, and you'll start seeing bubbles in the paint. Unfortunately, by the time you see the bubbles it's too late. The damage has already started. The good news is that there are wheel arch repair panels, and wheelhouse repair panels, that can help you fix this area. If you have a rusty wheel arch, this video shows you one way of repairing a rusted wheel arch.
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[@dragshoe9339]

Pretty much exactly what I need to do with my old bronco. Thanks for the expert technique. You make this job seem very approachable.

[@RaybuckAutoBodyParts]

Just take your time, and measure/trace everything out before you cut. Good luck.

[@alexrowdy2718]

Welding with naked hands is priceless !

[@esroot12]

This was an excellent video. Will be ordering from you guys-love that you have wheel arch parts not the entire panel.

[@digitalldreamer]

Amazing work! Old timer doing all the work needs to wear some type of REPORATOR, SUPER toxic! LOL

[@niiko_9161]

Just bought my wheel arches from you guys and I will definitely try some of these tips and tricks. Have a good one!

[@PREDATOR07]

Thank you so much for posting this video. I totally disagree with cutting the whole section in my case the driver side quarter pane due to the amount of work required when cutting the whole area.

[@leeirvin5983]

I recently bought 2 wheel arches and another lower panel from Ray Bucks. Top quality panels, made the job a 100 times easier. Thank you Ray Bucks. I recommend you to everyone I know.

[@RaybuckAutoBodyParts]

Thanks for the feedback. Glad you were satisfied and we could help with your project!

[@briardan9226]

I really like the way this was shown and narrated over the work. The music ... meh. But I don't really like background music on repair videos. Especially when it's repetitious. I could just be getting old and cranky. LOL Great video!

[@charvakkarpe]

This is great. I would have liked to see the paint blending steps too.

[@dennisgallear409]

Nice lesson for sure!

[@rustyshacklefordspocketsqu8162]

prime at 240- 320. 400 is the max, anything after that it peels

[@Klwjjj]

That’s one nice repair. Thought out nice and clean work.

[@monkey555500]

fab video...really helpful thanx

[@clterry07]

i like the editorial on rust and manufacturing ... yes sir you are correct on the foam spray for noise deadening ... dumb move but good for body shops lol

[@802reptiles4]

Thanks for posting

[@griffturfcare5061]

got the same problem, not quite as bad. good stuff

[@enriquelopez9124]

Awesome job,

[@mottersheadpaving]

excellent vid thankyou

[@jeremyjongejan]

Great video. Thanks!

[@kennyleejohnson5253]

Great video !!

[@JKargariyan-xl2lj]

Thanks

[@michaeln807]

How much does a repair like this cost?

[@davidd1395]

Better than new!

[@myworkshop1737]

Very good

[@ramirogarcia1045]

You can cut music fo future videos

[@annettesurfer]

That "chisel" is a Steck SeamBuster model 20015 and I'd use a wooden handle to help align the edges to weld rather than steel. I'm not a fan of lapping the patch, butting (like Fitzee on YT) would've eliminated 99% of the body filler. I would've used a panel bonding adhesive instead of seam sealer. Back to the SeamBuster, it's great to use as a can opener to remove panels from donor vehicles in scrap yards where torches and grinders aren't allowed. I once cut out entire wheel wells to transplant. Slices 'em out quickly. Using the Steck on a windshield pinch weld was a bit more difficult but doable.

[@littleredridinghood5622]

Fitzee fab is a master of butt welding .. Some of his body work requires 0 body filler ..

[@lawncuttingplusdelta]

Impressive practical repair , just as fast as mickey figerglassing , and metal piece is cheap 👍🏻

[@sdoyal1]

Good info but next time PLEASE CUT OFF THE MUSIC !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

[@janetc4306]

I liked the music.

[@spiffy830]

Great video MUSIC sucks had to mute

[@frundlemud]

Decent solid repair that will last.

[@Halfdaf]

Its overall a good job, but i did see some excess lines right on the contour as soon as he applied the primer and also saw it on the final pic

[@MediocreMedic123]

Does anyone know if these are quality parts?

[@_D.I.G_]

it happens on the 99-04 mustangs to bad there is no patch panels you can buy for those cars. I had to use fiber glass and bondo it didn't hold up well and i have to do the repair again.

[@onlywenilaugh6589]

Cutting wheel guard tool is your friend. That wheel breaks and it's going to embed in his head or face or wherever it hits. Thanks for the video.

[@kenj.8897]

Not to mention a fire blanket over the tire to protect the wheels finish from sparks .

[@possle]

How do you get the line in the repair piece so it slots under body? Is this method easier for fitting vs cutting the repair panel and butt joint welding it? The join on the inner and outer arch joint, is this welding together at all or just seem sealed

[@RaybuckAutoBodyParts]

The arch body lines are so close that you can slide this piece under the body and it will almost right on. Personally, I probably would have butt welded, but I think it's just a matter of personal preference. Everything in this repair was welded, but the inner panel patch that they put in was stitch welded and then seam sealed.

[@dustinterry6321]

I have the bubbles starting on my 2013 F150. The one bodyshop I took it to for a quick diagnosis said they would only replace the whole box side. Is the repair in this video common to bodyshops? Very satisfying video to watch BTW.

[@RaybuckAutoBodyParts]

That's not surprising. Some shops do not like to do rust repair work, so they tend to push for complete panel replacement. The repair shown in the video is very common, so I would suggest calling some other shops.

[@dustinterry6321]

@@RaybuckAutoBodyParts thank you!

[@shawn6684]

It rots out cause there's a foam strip they put in between outside and inside. 😫

[@cujo7240]

Nice repair work. My concern though is that the repair job took care of the obvious damage visible on the rear portion of the wheel arch, but what if there is similar damage farther forward on the front side of the arch that just hasn't made to the surface yet. Do all manufactures use this spray in foam sound deadening in these truck wheel arches?

[@RaybuckAutoBodyParts]

Our understanding is that most manufacturers use this spray. And yes, your concern is founded. There could be rust starting in a different area around the arch. I would highly recommend just doing the entire arch, instead of just a section of it as was done in this fix.

[@scottkavanagh8201]

I would've done the whole wheel arches on both sides because they'll eventually rust anyway.

[@figurado1]

This repair could last over a year. Then you get to do it again. If you use this approach you can plan to do it once a year until the entire vehicle composts.

[@tlabrusciano]

Hey Steve, where do you purchase your sheet metal, I need to order both side for my expedition, also what did they charge you to do the work so I have an idea. Truck turned out great..

[@RaybuckAutoBodyParts]

These types of panels are all from Key Parts. The work on my truck typically runs in the $700-$1000 range.

[@jamesgould6001]

Hello. Quick and final question. One side done, my inner wheel well did not need repair. Not so lucky on the other side, When you weld in new piece on inner, don't you have to weld up the tops where the notches are are??? Your new welded piece is only on the outside of the inner wheel well no notches. I hope I am clear. Thank you

[@RaybuckAutoBodyParts]

If I'm understanding you correctly, then yes, you should weld up anything that was previously a solid piece.

[@wadesoutdoors1914]

Great video !! Wondering why he done an over lap other than a butt weld ?

[@RaybuckAutoBodyParts]

Not sure. I would have done a butt weld.

[@deebee3901]

After a year, how is the repair holding up? Did you do the other side too?

[@RaybuckAutoBodyParts]

The repair is holding up well. I haven't had to do the other side yet. I've also been spraying Fluid Film around these areas in the Fall each year to help keep the salt off.

[@kenhilson786]

what about flanging the edges of patch that go underneath or does the misalignment help in blending the bondo

[@RaybuckAutoBodyParts]

Definitely. You could cut out just a bit more and flange in the flatter area around the arch.

[@dougkershaw2844]

a lot of work for something that will last about a year been doing body work for 45 plus years if you are going to keep the truck put new bedsides on the dam thing when you do all that welding you have burned off all the E coat on the back side then here comes new rust in less than a year

[@lcsvlone2811]

What is a new bedside? I am thinking of doing this on my car as it is very special to me how could I repair it on a car without it rusting in a year?

[@halledwardb]

What brand is that extended cut off tool. Looks like a great tool to have!

[@RaybuckAutoBodyParts]

Sorry, I don't know, but you're right. That would be a nice tool to have.

[@kaitlynsuarez5129]

Do you all sell wheel arch protectors for '12 honda accord lx's? Looking to protect it.

[@RaybuckAutoBodyParts]

Sorry, we do not have a wheel arch for that model year accord.

[@stevemaclean2009]

How was this painted? Was thr basecoat blended in and whole panel recleared or was who panel repainted with base and clear coated?

[@RaybuckAutoBodyParts]

basecoat blended and then whole panel cleared

[@boondock6055]

How much? $

[@jaggass]

Do rust bubbles always mean holes in the bodywork? My neighbour has a Mazda 6 with rusty wheel arches like that.

[@RaybuckAutoBodyParts]

Not always, but usually if there's a bubble, that means water is getting in from behind (which is typically from a rusted out panel)

[@2011wideglide]

I looked on your website but you don’t have anything for my 2016 ram 1500 bed wheel well. Just started getting rust. Well last yr and was thinking I should fix before it gets to bad.

[@RaybuckAutoBodyParts]

Sorry, that's correct. We don't have the replacement wheel arches for the newer Rams yet.

[@benchman1351]

You lapped it, well I guess you wanna do that repair again, I give it a couple years at best. If it's not butt welded and sealed from behind, you're doing it again, don't throw out the left over patch panel you'll need it.

[@lariat9447]

Definately not a long term repair, rust is still there and will form worse in the "overlapped" area.

[@clterry07]

question : how much bondo was used to fill in the seams especially were the body lines met each other ... thats the hardest part of rust repair are the body lines ..

[@RaybuckAutoBodyParts]

It was a light skim coat. Probably around 1/8"

[@jamesgould6001]

Between the inner wheel well repair piece lip and the new wheel house arch lip did you seal that, or what did you do?

[@RaybuckAutoBodyParts]

Yes, they seam sealed along that edge, and all other overlapping edges.

[@jamesgould6001]

@@RaybuckAutoBodyParts Thank You!

[@jamesgould6001]

One more question for you, since I have gotten my panels and am getting ready to start. What is "weldable primer"? Never heard of it before, and can't find it. My local part stores never heard of it either. Thank you

[@RaybuckAutoBodyParts]

@@jamesgould6001 We sell weldable primer. It's meant to be sprayed on before welding, and then it gets pulled into the weld to help keep it from rusting. Some people use it to coat the inner side of panels that are going to be welded together, but it's not really meant to protect those areas for the long run. Once welded together, something like a cavity wax, or inner panel coating really should be sprayed into these areas.

[@rightwinger1505]

Looks great but i hate the body filler idea. Is there any way to get the same results without using it? Heavy primer ect...

[@RaybuckAutoBodyParts]

Only real way around it is to metal work everything. Even with that, you'll probably still need to glaze it.

[@rightwinger1505]

@@RaybuckAutoBodyParts thank you for responding so quickly

[@sheetschandler]

What type of welder do you use for this type of body work?

[@RaybuckAutoBodyParts]

Typically you would use a MIG welder for this. If you were trying to buttweld the panels, you could use a TIG.

[@borischerniy4430]

what is this special red primer befor (and for?) welding?

[@RaybuckAutoBodyParts]

It's a weld thru primer. It helps seal the bare metal, and it won't burn off during welding like a standard automotive primer would.

[@f00tyfr33k]

Dude welds wkthout gloves then next minute wears gloves and his fking safety squints 😂 useful video regardless

[@oxygen454]

I'm kinda surprised the rest of the paint wants masked off. The hot sparks from the zipcut cutting embeds into the paint and rusts.

[@jordancrawford9397]

What kind of primer did they use? Couldn’t catch the name or kind in the video

[@RaybuckAutoBodyParts]

They just used a weld thru primer

[@PeterEgan-kc9ty]

Who let this man near a welder🤦🏻‍♂️ No mask on or gloves, might be old school but it's one way to give yourself melanoma. That repair is just going to rust from the inside out again due to that overlapped piece which will trap moisture and that skim of fibreglass will start coming away from the panel when it does. No manufacturers repair process includes overlapping a repair section unless it is for a plug weld or resistance spot weld on an aperture you can seal afterwards. It looks good for now but it will come back through worse as that inside edge is exposed.

[@tropifiori]

Can you do that with an arc welder? What amperage ?

[@RaybuckAutoBodyParts]

I would think so, but I'm not sure of amperage for it.

[@adriancarter825]

Great result but you skipped the base coat and lacquer

[@joemorgulec2012]

I’ve seen a lot of comments indicating that the overlapping metals will cause it to rust eventually. Is this true? Would it be more costly to have it done differently ? Thank you! I really enjoyed the video!

[@RaybuckAutoBodyParts]

With the overlap, I think it depends on how well you seal the area behind the patch. Personally, I would butt-weld the panels so water wouldn't be able to puddle anywhere. That said, it's been two years and the fix is still holding up.

[@joemorgulec2012]

Thank you for the feedback. I am going to call for some quotes on my job tomorrow. Would you recommend a welding and fabrication shop, or a collision/body shop for the best work at the best price?

[@RaybuckAutoBodyParts]

I would take it to a body shop

[@joemorgulec2012]

I know you’ve said that around $1000 would be a fair cost for the repair. I am getting quoted at around 2,500+ from shops I’ve called on and my rust is not even bad. It has not rusted past the body line of the wheel arch at all. What strategies can I use to find an affordable shop that does quality work. For context, I live in Port Huron, Michigan

[@RaybuckAutoBodyParts]

@joemorgulec2012 that seems high, but a lot of shops don't like doing rust repair, so they may price the job accordingly

[@liamwilder4669]

Is that a weather tech bed liner? If so do you recommend it?

[@RaybuckAutoBodyParts]

It's a factory Ford spray-in bedliner

[@liamwilder4669]

@@RaybuckAutoBodyPartssorry I meant to say the bed cover, not bed liner

[@RaybuckAutoBodyParts]

@@liamwilder4669 bed cover was just an inexpensive one from Amazon

[@s1003232]

this is not rust repair. this is rust replacement.

[@northerntoyota7584]

Why do domestic manufacturers use this double wall with foam method for bed sides? All Toyotas I’ve owned have single wall bed sides and I’ve never had them rust. Easy to rust proof and don’t trap dirt and moisture

[@andrewgilbride7546]

I guess the bodywork guy doesn’t care about his lungs.

[@immytay65]

Have any Raybuck coupon codes for body panels?

[@RaybuckAutoBodyParts]

5-200 gets you 5% off orders over $200. There's also a sale going on right now.

[@imsorrydaveimafraidicantdothat]

Why are wheel wells designed this way? It seems to be a perfect environment for rust to develop. Planned obsolescence seems like the most likely reason.

[@ToyotaLandCruiser]

That will rust/bubble soon. Use epoxy paint below putty! How’s the inner/outer panel seam done? Maybe still open?🤦🏻‍♂️ Not a good example at all. Just regular fast job before selling.

[@RaybuckAutoBodyParts]

This is my daily driver. One year later and it still looks good.

[@norsia1946]

You have no clue what you're talking about, and it shows.

[@scottalexander5809]

Did he paint and clear the entire bedside?

[@RaybuckAutoBodyParts]

He painted the area around the repair and then cleared the whole bedside.

[@carr2oman103]

👌

[@benpolman2365]

Just a question, as I have become a victim of the wheel well rust, what would be a labor cost for something like this, and total cost after everything?

[@RaybuckAutoBodyParts]

It's hard to put an exact amount on a project like this as it's variable, depending on the amount of rust that needs to be repaired, the cost of the parts, and the labor rate of the shop doing the work. Roughly, though, it's probably going to be in the $800-$1000 range.

[@shalee48]

Take the tail lights out and spray oil in there and it will never rust ,Tim

[@michaeldunagan8268]

NOTHING SHORT OF FASENATING! I like how you narrated to explain what he was doing. All in all: I'm estimating he charge 3 hours of Labor. I'm going to call it $45 an hour. So that's $135 in labor. I don't know what the material cost would be but I'm just going to add another $65 for the paints and primers and body fillers. Is this the less than just getting a whole new side of the panel? I'm going through this on my 1999 Toyota Solara. It's a beater...🤷 But online aftermarket has the driver side front fender for around $70 and Toyota has it for about $160. I believe in both instances that's just primered and I'll still have to paint the thunder. I just pushed through the rest today and it's about a 2 by 3 inch hole. Maybe I'll try one of those fiberglass big-box store body Bondo type things....dunno.... But I damn sure don't have the skill to do it as good as this video showed.

[@Aman-rp7yj]

So there is no possible way to prevent/seal the issue area?

[@RaybuckAutoBodyParts]

Yes, you can remove as much of the foam as you can reach and then spray that area of the bed with undercoating or cavity wax. You can also topcoat any of that with a product like Fluid Film on a yearly basis. There's no guarantee that any/all of this will prevent rust from forming, but it really helps.

[@Aman-rp7yj]

@@RaybuckAutoBodyParts thanks for the response. Starting to have slight bubbling on my 09. Really frustrating seeing as I took good care of it.

[@RaybuckAutoBodyParts]

@@Aman-rp7yj Mine was a garage-kept 12 and it did this. It's really frustrating that the manufacturers won't change their process to eliminate this problem. You don't see this problem on older trucks that didn't have the foam spray.

[@andrewgibb8846]

The body shops in my town want $1200 per arch for repair. It’s involved but man, customer supplied parts it’s just labour and time. I need to learn how to weld.

[@swellscity5792]

Too much work but nicely done... might just get a fender cover

[@chrisgivboi]

What does something like this cost a customer? I have a similar wheel arch that I want professionally fixed

[@RaybuckAutoBodyParts]

You're most likely looking at $700-$900 for a repair like this.

[@chrisgivboi]

@@RaybuckAutoBodyParts Thank you for this information!!

[@keithbrown1915]

Not recommended. The rest of the quarter will rust out later. Replace entire quarter or use engine patch and remove the awful sound deadner. Not sure why there has not been a class action suit against Ferd under lemon laws

[@rangerwwc72]

Ballpark, what would this cost at a body shop?

[@RaybuckAutoBodyParts]

Probably in the $800-$1000 range

[@rangerwwc72]

Why wouldn't you do the whole wheel well to stop any more rust coming through?

[@RaybuckAutoBodyParts]

When doing a repair like this, you want to cut beyond the rust in order to prevent it from spreading. The best approach would be to replace the entire bed skin, but that is a much more costly project, hence the availability of smaller patch panels.

[@paulcohen142]

Everyone has a different budget, some people may only have one car too and can’t afford for it to be off the road

[@Darkelementsx22]

how much does something like that cost? just fixing it not painting.

[@RaybuckAutoBodyParts]

All in, this repair was around $750, including paint

[@binarywraith]

Got his safety squints on doing the tacks I see.

[@gthree0239]

Why didn’t he place the new panel then do a cut and butt? Weld that seam fully closed and then you have zero percent chance of water getting behind the body filler. At that point you can use minimal body filler and have a smooth surface. The way he’s doing it you have to build the repair back to the surface with filler. Seems like it’s defeating the purpose of using the premade body panel. If you’re using that much filler go ahead and fab your own wheel arch.

[@hawkgeoff]

Cost for a repair like this?

[@RaybuckAutoBodyParts]

Probably in the $800-$1000 range

[@susanrico4470]

How much is the repair

[@RaybuckAutoBodyParts]

This type of repair will typically run in the $700-$1000 range

[@jiggidyjam]

What was the cost to do this?

[@RaybuckAutoBodyParts]

You're most likely looking at $800-$1000 to have something like this done.

[@jiggidyjam]

@@RaybuckAutoBodyParts thx

[@bodeine454]

You would think that these manufacturers would come up with a better way to do their fenders especially knowing that they almost always start rusting there. I'm looking to buy a used truck, been looking at Dodge Rams hard, and it's hard to find one 10 years old that doesn't have rust all in the fender wells. The rest of the truck can look great but those fenders are a different story. Turns me off from wanting to buy one. I'm not really a body man although I do have a tig welder and a cheap wire feed welder. What worries me the most about doing it is matching the paint and blending it in...

[@Ionizap]

My thoughts exactly. Bought a 2017 Silverado here in Canada 3 years ago and now one side is rusted bad. Why can't the manufacturers do something about this? I had a 2010 GMC Acadia for 10 years and not a spot of rust on it.

[@justinpennington7682]

They did . Aluminum

[@bodeine454]

@@justinpennington7682 Which one uses aluminium? Too little too late in my opinion. I changed my game plan since then anyway. Bought one of the best cars on the road instead, an '02 Lexus LS 430, not a spot of rust anywhere and drives like a dream. A truly amazing car.

[@justinpennington7682]

@@bodeine454 Ford

[@bodeine454]

@@justinpennington7682 I didn't know that, thanks for the info.

[@wD-io9nd]

Great video but clearly you cut the piece to short if your goal was to tuck it under 😅

[@RDRAMG]

What is a average price for a repair like that?

[@RaybuckAutoBodyParts]

Most likely in the $700-$1000 range

[@RDRAMG]

@@RaybuckAutoBodyParts thank you for the reply

[@HUBBABUBBADOOPYDOOP]

Those bubbles are caused by the _oxidation_ of the metal; it is literally pressurized oxygen.

[@Jursaw]

How much did this repair cost you?

[@RaybuckAutoBodyParts]

You're probably looking in the $700-$1000 range for a repair like this.

[@DonTem-rb5bh]

If you want to repair that area why would you go and buy flat stock and make it from scratch or buy a large panel like the one you're selling? Just go to your friendly neighborhood junkyard and slice out the appropriate section from a front fender which has the same contour and body line as the one you're selling. The Ford front fenders never rust from the inside out because they are single wall. I'm about to do that on an a 2007 F150

[@bobadingo]

Never ever use body filler on bare metal !! epoxy or metal etching primer must go down first!.. .

[@daleprice8161]

Who is the manufacturer of y'all's sheet metal

[@RaybuckAutoBodyParts]

Most of our wheel arches are made by Key Parts.

[@daleprice8161]

@@RaybuckAutoBodyParts I thought I had seen AMD on the video

[@daleprice8161]

@@RaybuckAutoBodyParts just wanted to say I have recently ordered partial door skin for a 2006 caravan the panel at excellent quality was very very satisfied .. at the end of this month I will be placing another order for the other side the density of the metal was great the one quality i look for with any part ...dale

[@RaybuckAutoBodyParts]

@@daleprice8161 thanks for the feedback Dale. Very glad you were satisfied with our parts. Merry Christmas

[@Rayrayjr1970]

What size wire is that .30” ?

[@RaybuckAutoBodyParts]

Most likely

[@BlacknRedSN95]

I had to go to a junkyard and disc cut my own patch panel out of an 01 mustang because no one makes the panels for my 2000 mustang

[@MarcYanOfficial]

Shouldn’t he have worn a mask for the sanding part?

[@JemenJ]

Just breath all that dust in...