Patched My Fender Well Holes - DIY Instructions & Photos

[Ciulster]

@Ciulster ..... not so fast on the draw. Geez buddy did you wake up on the wrong side of the bed. FYI Hein had to get the blueprints from Ford re-configure them to have his CAD accept them, run multiple attempts, determine the best composite and materials to attach them to the felt surfaces, stock and ship them and include the JB weld and the foam inserts for 100 bucks. He is doing this as a favor to us. My son has a CAD/Router/ 3D Printer fabrication company and he said Hein is a saint for doing this when he has a complicated business to run. I have spoken with Hein - he is a class act So, IMO you don't know $hit about this situation. BTW -there IS or last week there was a link to ship to Canada and the cost was more than reasonable. Get some sleep grumpy!

I apologize, you're right. My tone was a bit aggressive there. I am just so sick and tired of being nickel and dimed at every corner especially when it comes to parts that in theory should be cheap, but aren't for one reason or another. Just running some quick math, in my experience almost anything coming cross border these days runs about $60USD for some reason but let's say I found a way to get free shipping. At today's conversion rate after tax and duty I'd still be looking somewhere in the ballpark of $150-$170 to fix an issue that shouldn't be present on a vehicle I have literally been budgeting to the max to be able to afford. Not to be a broke whiner but I have been taking as much overtime and cutting out as many meals as I can to make sure I can comfortably make my payments without any nail-biting and sleepless nights... and this is just another headache that I shouldn't be having to deal with in the first place.

I am going to go have some words with my dealer and see if I can get them to get Ford corporate to do something about this on their dime. If anyone deserves my wrath it's them, not the guy providing the solution, even if I don't agree with the pricing. Worst case Ontario I found a rubber mudflap that is 1/4" thick and 4' x 4' for like $16. Just cut that to cover the holes half decently and send it.

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[MAT1955]

@Ciulster ..... and I apologize too. I was too quick on the draw myself. I apologize and I'll get some more sleep myself :-) I understand the parts 100% and as a long time Ford owner (3 mustangs) I was pi$$ed after spending 70 grand and looking at those holes and the chipped paint on my pinch welds and K frame. How did a line worker not notice that and if their seeing eye dog didn't point it out for them, where was quality control? Don't know where you are in Alberta. I lived in Calgary for a bit. Is there any way you can open a UPS box at an American city near the border, have a friend scoot across and pick it up, pay some duty and ship it to you? I'd do it for you if I was closer. I have never messed with the brokers they are vampires. I have a UPS address in N.Y that I use all the time. Most of the time the customs agents won't even collect tax under $200 as it's too much paperwork and overtime. - just doesn't pay. Your solutions are great ideas and I considered them until I looked at the profile then I went crap that isn't going to be easy. If you've seen Tony Unica's video he fiber glassed the holes but it took some serious time and effort. I guy I met at a Mustang meet got a used truck innertube cut a big enough patch plus one inch around the perimeter, cleaned it with acetone and managed to do a pretty decent repair using I thing copious amounts of that yellow weatherstripping glue. After it dried (like 48 hours) he put either black Sikaflex or 3m Black marine silicone on it. That was four months ago. It was on at Iast Saturday's coffee meet. I bought two kits but my dealer asked for one for a 2024 Dark Horse that they are trying to sell.....and the 38% dollar difference doesn't help. Good luck! Be interesting to see if Ford corrects for 2025.....and how they will handle the 2024 error? - because if they don't fix this issue now THAT would be a course in 101 stupid. Frame damage law suits should be a cake walk in five years or sooner. Frame parts will be rusting away "out of sight" under those covers! Come on Ford, you guys have a magnificent car here, you read these comments. Get on the phone to Hein and ship kits to the dealers. heck I bet 80% of the guys/gals will do the repair themselves OR start saving some serious money for the coming lawsuits. Get it right sooner than later, Ford! .....Just sayin'

 

[UNSAFE]

So how did you guys clean out the cavity prior to installing the kit? Vacuum with a narrow hose? What's the trick?
TIA!

Good question.

 

[Wiley Marmot]

Just ordered my kit. Free shipping!

 

[Grabber1]

So how did you guys clean out the cavity prior to installing the kit? Vacuum with a narrow hose? What's the trick?
TIA!

Yes a small flexible vac hose works. If you have a lot of debris you can take the tire off to get better access. I used a small automotive mirror tool to look inside the hole with the tire on.

 

[MAT1955]

@steveo1960 ..... sorry to take a few days to reply. If you didn't drive far a shop vac with a with an extension wand will do. That worked for me. Then clean as much of the remaining grit off with a rag. A friend drove for a couple of months and had to put it on a hoist and remove the bottom fiber panels because there was so much crap along the pinch welds under those fiber panels. He got it done then did some paint touch-ups and after that sprayed the area with a clear oil (not the gummy stiff) I think he ordered Corrosion Free (that's what I used) then installed the DIYvan.com patches.

 

[steveo1960]

@steveo1960 ..... sorry to take a few days to reply. If you didn't drive far a shop vac with a with an extension wand will do. That worked for me. Then clean as much of the remaining grit off with a rag. A friend drove for a couple of months and had to put it on a hoist and remove the bottom fiber panels because there was so much crap along the pinch welds under those fiber panels. He got it done then did some paint touch-ups and after that sprayed the area with a clear oil (not the gummy stiff) I think he ordered Corrosion Free (that's what I used) then installed the DIYvan.com patches.

Thank you !

 

[Illini4]

I'm preaching to the choir, but it's pretty infuriating that we have to go through all this on a new car. I know Ford has people that monitor this site, yet they do nothing.

 

[Grabber1]

I'm preaching to the choir, but it's pretty infuriating that we have to go through all this on a new car. I know Ford has people that monitor this site, yet they do nothing.

Yep. They comment on other threads but Ford won't touch this one with a 10 foot pole.

 

[MAT1955]

@Illini4 ..... you are 100% right that Ford monitors this site - which is smart of them to get knowledgeable insight from the most educated Mustang owners in the 'verse. I'd also bet a load that there have been some discussions at Ford as to what the h3ll someone was thinking when they let those slip by. I would like to see our homies at Ford say "oops, sorry y'all, if you fixed it here's a credit for an oil change etc. If you haven't yet done so here's a credit number for Hein at DIYvan.com to order your kit and then take it to your dealer." What I hope I DON'T read is some corporate BS excuse as to why the holes are there - I think Ford is better than that and we are sure smarter than to eat some BS - as well, we deserve better.

 

[Wiley Marmot]

Yes a small flexible vac hose works. If you have a lot of debris you can take the tire off to get better access. I used a small automotive mirror tool to look inside the hole with the tire on.

When I fell "victim" to one of the innumerable Shark Vacuum Cleaner infommercials a while back; I ordered the optional computer/car detailing micro attachment kit. Should be able to get into that rascal and suck out any small debris (I hope). Figured I might have to take the wheel off; we'll see.

PS: ford could make this right by comping us an all Ti Akropovic exhaust!

 

[ListedGuru]

After the repair was completed I put on my rock guards.

What rock guards are those? Also did you put them on the back too or just the front?

 

[Grabber1]

@ListedGuru.
Yes I did put them on the back too. I posted a thread about these rock / mudguards which can be found on this link: https://www.mustang7g.com/forums/threads/installed-4-zl1-s650-delux-rock-guards-photos.163401/

 

[Zig]

 

[roadpilot]

How did a line worker not notice that and if their seeing eye dog didn't point it out for them, where was quality control?

I hate to break this to you, but those who work on the assembly line do not design the vehicles. They build them how the engineers design them.

Anyone who thinks these were simply "overlooked" or "missed" by the engineers knows NOTHING about the design and engineering process.

Point being: Your blaming the wrong folks.

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