RamAirThree

Here is a step by step procedure to help members either do or learn whats involved in hanging a new quarter panel with any car since most of us drive more than just F-bodies. Again these are steps to start and complete the job, any techniques to improve the work and speed up the process will have to be learned through experience by you, as technique tends to differ between individuals. Hope everyone finds this informative and helpful.

1- IMPORTANT Make sure all adjacent panels are in alignment and where OEM specifications recommend they should be before removing the quarter panel. So now is when you make your pulls and do your dolly and hammering.

2-Remove rear light, taillight assembly, filler panels, Quarter glass, fuel filler neck and the rear bumper if required.

3-REMOVE GAS TANK IF SAFTEY IS AN ISSUE

4-Remove loosen or support rear decklid if needed.

5-Reposition away or remove any wiring, electrical parts, weather stripping and interior panels with carpeting positioned away as far as possible..

6-Now would be a good time to remove any exterior moldings or trim as well if needed.

7-Find and identify all spot weld locations... mark new panel locations if needed.

8-Determine the location to cut inorder to seperate the roof to quarter panel joint.
You might want to follow the vehicle maker's recommendations if needed or allow a 1/4" overlap on new panel atleast.

9-Drill out the spot welds using a 1/8" drill bit. It is important not to Damage parts attached to the quarter panel which are not going to be replaced.

10-Remove any foam fillers or sound deadening pads from the weld joint areas.

11-Cut the roof to quarter panel weld joint slightly longer than the final cut area. Avoid heating the panel to avoid any panel warping.

12-Remove the damaged quarter panel. This might also require an air chisel or second set of hands with a hammer and medium chisel.

13-Trim back any remaining edges to the exact cut location if required.

14-Using a dye grinder or similiar tool remove any burrs or spot weld nuggets from the mating surfaces, now repair any damage if correction is seen needed.
Avoid removing any zinc coating

15-Using a hammer and dolly to straighten your mating panel edges if bent or if not in proper position, this is a must to insure a proper fitting with the replacement panel.

16-I would recommend keeping a spray bottle with water or atleast a small bucket of water along with a fire extinguisher close by with the next steps. Better safe than sorry.

17-Perform a trial fit of the replacement panel to the car to make sure all mating surfaces are properly aligned.

18-You will want to clean the weld mating sufaces now. I tend to use a small dye grinder inorder to have better welds. I only hit the dye grinder on the spots where the welds will take place. On some panels though you must avoid zinc coating removal.

19-Refer to the vehicle maker's body repair manual for the recommended welding method. Squeeze type resistance spot weld should only be used along factory seams when recommended by the vehicle maker.

20-You should also refer to recommended location, number, and size of plug weld holes from manufacturer's specifications (some cars may differ), but if no recommendations available or found, standard practice is to drill 8mm or 5/16" holes in the outer and/or upper panel at the same locations used by the original panel. If using a lap joint, allow for a minumum of 6mm or 1/4" overlap.
If using a squeeze type resistance spot weld, refer to the vehicle maker's recommendations for the electrode diameter, weld locations, and spacings , etc.

21-Test fit replacement quarter panel using minumal clamps checking for perfect fit and proper gappage once more and remove

22-Apply weld-bond material when recommended by the vehicle maker in the specific joints adviced.

23-Fit the replacement quarter panel in proper position and securely clamp it into place.

24-Use adjacent panels to verify that the assembly is properly aligned.

25-Make test welds first in locations using common sense and if all shows well after inspection, make the required welds to finish up job.

26-Verify with adjacent panels that the quarter panel is still properly aligned and then dress your welds if need be.

27-Then carefully finish your joint areas, remember you do not want to heat the panel and cause warpage.

28-Apply corrosion resistant primer to all interior and exterior surfaces involved by repair that have bare metal exposed or even paint finish removed.

29-Apply the seam sealer to all your inner joints to protect against corrosion, deaden sound, keep water out, and restore original appearance. Prime or speckle coat where required .

30-grind down your welds to look factory and do your body work that is needed prior to painting. Miniumal body filler should be needed on a correct job, even in the roof to quarter panel joint.

31-Any other anti-corrosion compounds that are needed may now be applied.

32-Tape off and prime whats left to be primed and cut in your edges with base coat color of vehicle

33-Replace your foam fillers and sound deadening pads as well.

34-Reinstall your gas tank and fuel filler neck if removed.

35-Reinstall your interior panels and reposition your carpet back.

36-prep and paint your new quarter and adjacent panels.

37-reinstall your quarter glass and trim, moldings and taillight assembly and reinstall all electrical and components with any other reassembly that might be involved.

38-Congratulations your done!

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1970 Formula 400 RAIII / Muncie close ratio 4-speed / 3:90 Limited Slip 12 bolt Rearend.

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Life's journey is not about arriving at the grave safely in a well preserved body but rather to skid in sideway, Totally worn out, Shouting HOLY S**t........ WHAT A RIDE!!!!!