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Old 05-07-2021, 10:18 PM   #1
OldCarNewTricks
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Default 242 Wheel Arch Repair

Many many years ago, my 242 was side swiped in a parking lot while under the ownership of the guy that got me into Volvos. I did an amateur Bondo job 6 years ago, and I haven't owned the car for a few years. Now that I own it again, I would like to fix it correctly.

Multiple sources sell wheel arch panels, but are listed as being for 4 door cars only. Seems to me that a major part of the patch panel can be used on my car, as I don't really see any difference between the arches on the two and four doors. Anyone know for sure?

I've done patch panel welding with my flux core wire welder before, and it works OK, but heats up the surface faster than other methods. This caused a bit of warping. Any suggestions from the more experienced?
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Old 05-07-2021, 10:23 PM   #2
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The mistake most people make when purchasing a patch panel is they think they need to use the entire panel. Just cut and use the smallest section that will do the job. As for warping, slow and steady, a spot weld here and there. Cool the panel as you go either with air or a damp towel.
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Old 05-08-2021, 02:46 PM   #3
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Skandix used to sell a 2dr repair panel from Klokkerholm. The main difference is the amount of side metal is a little more than the 4dr panel. The shape of the arch is the same as you mention.
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Old 05-08-2021, 03:05 PM   #4
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Which side? If passenger, get in touch with Rainbow Auto Service. They have a NOS rear quarter for a 1979-84 242.
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Old 05-08-2021, 05:38 PM   #5
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Which side? If passenger, get in touch with Rainbow Auto Service. They have a NOS rear quarter for a 1979-84 242.
I'm looking for a passenger side! I will contact them for sure!
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Old 05-08-2021, 10:20 PM   #6
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Pull it back out with a stud gun and mud it again.
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Old 05-09-2021, 04:02 PM   #7
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Pull it back out with a stud gun and mud it again.
This would work okay, but I'm not sure I can get the shape of the wheel arch edge correct.

Last edited by OldCarNewTricks; 05-10-2021 at 12:10 AM..
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Old 05-09-2021, 05:12 PM   #8
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This would work okay, but I'm not sure I can get the shape of the wheel arch edge shape correct.
It's supposed to look like a mirror image of the other side.
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Old 05-09-2021, 06:25 PM   #9
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It's supposed to look like a mirror image of the other side.
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Old 05-11-2021, 09:37 PM   #10
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Rainbow Auto Service has an entire quarter panel for $300. Not sure if it's worth it.

Anyone in Oregon or Southern WA have a 242 that they are parting out with a good passenger quarter panel?

I have a slide hammer which has the body puller screw attachment. I might see about fixing it up instead.
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Old 05-12-2021, 05:39 PM   #11
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I wanted to post a few pictures to show how extensive the damage is. I used my heat gun and a chisel to dig out some of the Bondo. I cannot believe how much I used back when. I remember there being some rust damage, but it is more severe now. Seems like alot of the arch is rusted out now.

I used a paint pen to outline the damaged area, and I marked my estimated depth of Bondo, IOW how far the dent would have to come out in that area. So I now know that the arch will have to be cut out regardless... My two options are to either get a 244 wheel arch panel, cut out the damaged metal and beat out the rest of the panel, and that would be a total of $80 or something. OR I can do 7 hours of driving to go grab the entire quarter panel that Rainbow has for $300.

Does anyone know how the quarter panels are attached? Are they just spot welded on?

I am hoping that some of you more experienced with body work can give input on the best option and how to go about this repair. Thanks! https://i.postimg.cc/3xTPNV4Q/20210512-111145.jpghttps://i.postimg.cc/76wvRc4N/20210512-111138.jpg
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Old 05-12-2021, 06:04 PM   #12
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*just* spot welded on.



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Old 05-12-2021, 06:22 PM   #13
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Did you check in with Skandix like I suggested? They were selling 2dr wheel arch repair panels. The shipping is a bit of money but it includes a good amount of weight. So, you could order some other things that would be included in your shipping. They speak english and are good folks.
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Old 05-12-2021, 06:36 PM   #14
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Originally Posted by dl242gt View Post
Did you check in with Skandix like I suggested? They were selling 2dr wheel arch repair panels. The shipping is a bit of money but it includes a good amount of weight. So, you could order some other things that would be included in your shipping. They speak english and are good folks.
I had not. Just did. Looks like the quarter panels are all gone and discontinued. However, the 242 wheel arch repair panels are still being made! Good suggestion! Maybe if/when I chop away the damaged wheel arch area, I will have access to the back portion of the dent, so I can get something behind it?
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Old 05-12-2021, 08:45 PM   #15
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As you said, shipping is quite spendy. I'll try to figure out what else I need if I go this route.
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Old 05-13-2021, 09:58 PM   #16
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Free wheel arches here
https://forums.turbobricks.com/showthread.php?t=360299
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Old 05-13-2021, 11:14 PM   #17
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somehow they are still worse than mine! Love the "wave" shape they have
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Old 05-14-2021, 09:08 AM   #18
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Practice. Turn down the heat on your welder. Make your own patch panel. You can make it in three sections. The top, curved section cut and hammered to shape. Then a flat outer section, cut into an arch. And finally the "under section". Weld each section one at a time. Or get a front fender and cut out the section you need. You should be able to make it work.
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Old 05-14-2021, 12:48 PM   #19
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Originally Posted by nel621 View Post
Practice. Turn down the heat on your welder. Make your own patch panel. You can make it in three sections. The top, curved section cut and hammered to shape. Then a flat outer section, cut into an arch. And finally the "under section". Weld each section one at a time. Or get a front fender and cut out the section you need. You should be able to make it work.
Would it be a good idea to cut the damaged part out and reshape it, then weld it back in? I could then get the fender like you said from a JY and substitute the good arch for the rusted one.
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Old 05-14-2021, 01:45 PM   #20
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Yes, cut out he damaged section. Measure twice cut once , get a good close fit. Then spot weld here and there until all done , grind and body work and done. Keep the welded are cool. @ , 3 welds, cool, 2,3 welds, repeat.
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Old 05-14-2021, 01:52 PM   #21
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Good info from this guy. check out a few
https://youtu.be/ZdigwBNKFfI
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Old 05-14-2021, 10:05 PM   #22
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Originally Posted by nel621 View Post
Yes, cut out he damaged section. Measure twice cut once , get a good close fit. Then spot weld here and there until all done , grind and body work and done. Keep the welded are cool. @ , 3 welds, cool, 2,3 welds, repeat.
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Good info from this guy. check out a few
https://youtu.be/ZdigwBNKFfI
Thank you for the tips. This is definitely the least expensive option, albeit the most involved. Finding a fender from a 240 is easy enough. So the front matches the rear enough that I can chop and swap the arch?
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Old 05-14-2021, 10:23 PM   #23
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Quote:
Originally Posted by OldCarNewTricks View Post
Thank you for the tips. This is definitely the least expensive option, albeit the most involved. Finding a fender from a 240 is easy enough. So the front matches the rear enough that I can chop and swap the arch?


https://www.picknpull.com/part-prici...anel%20section
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Old 05-14-2021, 11:02 PM   #24
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Ouch, fair enough. More spendy than I thought.
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Old 05-14-2021, 11:04 PM   #25
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$100 is chicken feed to a real car guy.
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