This is the broken area.  You can also see another missing piece where the exhaust fell off and broke through.  I repaired that on the underside only for now and will deal with the external body side when I do the exterior prep.  My approach to fixing this involved pressing the wet fiberglass between two pieces of plywood covered with wax paper.










I made a form for the inner support.  After cutting it out I covered the edge and one face with wax paper.



















I sanded and tapered the repair area.  Once I mixed the epoxy and began wetting the mat, I didn't stop to take any pictures.  Basically, I started laying the mat on the roughened inner area shown at the left.  I built it towards the rear until about an inch was sticking past the flange.  Then I used spring clamps to hold the form I made against the inner surface of the flange and folded the mat up against it.  I kept building the mat onto the form until the required space was filled out.




Once I had enough material to form the repair, I put the second piece of plywood in place and squeezed them together.  I used a paint stirrer to keep the plywood separated on the outer edge.















After the epoxy cured, I removed the press.














I used the other side to make a stencil for cutting the fiberglass.  I made sure the stencil contained two holes so that I could get the third hole properly marked.  I'm using the single piece bump[er cover retainers so all the holes must line up.










Clamp the stencil in place, use a sharpie to trace the outline, and cut away the excess with a dremel.





​​









Here's the repair after drum sanding and drilling.














SUMMARY:  Though the repair was easy to execute, I had to come up with what was, to me, a novel approach.  I'd give this a 3 out of 10.

Early in this project, one of the first things I did was remove the rear bumper cover and bumper.  While in the process of removing the cover, I realized that the flange had been broken at some point in the past.  It was not just a matter of gluing it back on as it was shattered and pieces were missing.  The walk through below details how I repaired that area.

Rear Bumper Cover Flange

​Back to Rear Undercarriage                 Back to Progress So Far