The bucks are made from Home Depot MDF board. Two 3/4 inch pieces glued & screwed together. The profile or shape was taken from the right inner wheel well to match the recess or spot weld area of the old inner fenders. I like symmetry so I duplicated the right side in reverse to replace the left and eliminate the ugly fuel filler bump. The radius is from a 1 1/4" radius router bit. I will use these bucks again for the outer half of the wheel tubs. The right inner will become the left outer buck. I am doing the outers also for clearance issues. The stock outers have a bulge at the front area that will rub just before full suspension compression. I will do this work when I replace the rear quarter panels. After blasting I found no less than three patch panel and a pound of mig wire hair on each rear quarter panel. I used 16 ga. which is probably over kill but I felt with the depth of the new tubs(9.5") compared to the OEM units(5") the added stiffness would be an advantage.
There are more pics at
http://s250.photobucket.com/albums/gg247/ChevyIIPost/