You ever had one of these happen?  

 

I was test fitting my front passenger fender and went to put the one of the M8 bolts in - the one that goes into the front of the rocker on the bottom right behind the front wheel.  It was a little tight but not bad.  As I'm turning the wrench - snap!  The weld on the nut inside the rocker breaks.  My first thought was, "Oh sh1t!  How am I gonna fix that?" followed by, "do I REALLY need that bolt.  Of course the last thought was, "Do it right!  You've come this far."

 

So long story short, I had to cut the bolt, remove the fender, cut a hole in the rocker, weld a new nut in and then weld the rocker shut.  It took me about 3 hours and pissed me off a lot.  I was done with that stupid rocker and had already painted it (you can see the offending rocker in my avatar before I cut it up).  

 

I thought it might be interesting to hear some of your stories.  Please share! 

Yep. I've done that 2-3 times. The car I'm finishing now was repaired by using some metal mesh, a rag and bondo all stuffed into that cavity. A couple big wood screws held the fender on.

 

Chuck