Quarter Panel Install

Both quarter panels had major rust and dents. Areas on the quarter panels had bondo nearly 3/4" thick. The edges around the wheel well openings were completely rusted away and previous repairs consisted of forming bondo to appear as though the metal was still there.

I started the repair by cutting the quarter  panel enough to be able to remove the rear inner and outer wheel wells (see picture 3 below). Next I overlayed the new quarter on top of the old quarter panel and scribed the edge of the overlap.  I removed the new quarter panel and marked a new line 3/4" inside the line I just scribed and cut the old quarter panel on that line. After fitting the new quarter panel on that 3/4" overlay metal and achieve a perfect fit I drilled holes  and fasted the panel using clecos (see pic 5 below).  Next I used a thin cutoff wheel and would cut about 6" at a time on the edge of the new panel, I was then able to push in the NEW quarter panel edge to be in alignment with the edge of the old quarter panel and place a spot weld about every 2 inches (see youtube fitzee.fabrication, cut and butt video to see how this works) I would repeat this process until I made it all the way around the quarter.  Every time you cut the edge of the old quarter remember that you are leaving a 3/4" strip of (original quarter panel) sheetmetal that needs to be removed inside the car.