The job is done and it seemed to work out well.
I took a drive today along a road where I usually get tire rub and it was as smooth as if I had stock tires on the car.
Now for a little contrast, look at the stock ridge:
In some twist of irony, the left side turned out better and has more clearance.....The
right side was the one that rubbed the most. No matter. I gained enough room to drive with 3/4 tank on a bumpy road and have no contact. I could probably have a couple of robust buddies ride in the back and still be okay. It isn't just the matter of sidewall scuffing that worried me. It was that hard contact could buckle the quarter panels at the wheel opening edge when the wheel tub gets pushed up on contact.
I barely had enough of the spray on undercoating to do both sides. I bought 2 gallons from Resto Rick awhile back and used some on a couple of cars. I have had trouble here with some stuff going bad in the can. No matter how well I think that I sealed the can, some stuff stays good, other stuff hardens in the can. I've lost primer, body filler and half a can of undercoating to early "hardening".
Total cost?
Hmm.....Probably $40 for the wheel tub sections that I got from the self serve junkyard, $40 for welding wire and tips. I already had the grinder discs and saber saw blades. The 1/2 gallon of sound deadener/undercoating maybe cost $50...?
For less than $130 I have the clearance to drive the car without worry.
SCORE !
If you have wide tires in your car and want more clearance than the stock setup allows, this wasn't all that hard to do.