The passenger lower quarter panel was heavily pin-holed with rust and although I had previously attempted repairs here it was in need of replacement. This is another scenario where the replacement part is readily available in a high-quality reproduction at a reasonable price; so it wasn’t worth chasing pinholes in paper-thin metal when a far better repair could be made with less effort by replacing the whole section. Removing the lower quarter panel also gives access to the outer frame rail so that a minor dent in this area can be fixed; this will also allow priming/rustproofing of the interior surface.
I had been putting off disassembling the front bumper for a while but it had to be done so that it can be ready for primer during the next big primer phase. Every screw and bolt was solidly rusted to the bumper and the rubber rub strip was dry-rotted solidly into it’s aluminum trim piece.
The bus was moved 90 degrees again to the other garage bay. The original bus bubble worked well but had the disadvantage of blocking both garage bays. The new-and-improved version only takes up one bay while staying roughly the same size inside. Structure was also added at key points to prevent the sides from sucking in too much when the exhaust fan is turned on.
For the first time in this project something new is going onto the bus rather than coming off. (patch metal doesn’t count) Everything inside & out above the trim line was coated with epoxy primer. The epoxy primer creates a barrier between the bare metal and the surfacing layers and topcoats that will follow. Despite careful cleaning and tack cloth usage a good bit of lint/trash ended up embedded in the epoxy. This contamination was caused by the roughness of the bare metal pulling lint off of the cleaning clothes; since the epoxy is smooth this shouldn’t be a problem with the remaining coats.