How To Replace/Weld In Body Panels.

Another common problem with older cars is that some of the body panels tend to be rusted out or dented. I will be explaining how to replace them.

The process for replacing body panels is fairly simple. It just requires some amount skill in welding and in cutting.

The first step of this process is to line up your replacement metal with the part on the car, this will help you make sure you have the right part, and to make sure you get an idea of where you can cut the old panel out.

The second step is to tape up where you want to cut the metal. This tape line should be in a spot that allows you to cut out all the rust or dents, but still having enough metal to cover the entire area. This tape line also helps to keep the cut straight.

The next step is to start cutting. You can use a variety of tools, but I will be using a pneumatic die grinder. Cut about one millimeter below the tape. Be sure to cut the line completely across the metal before cutting completely through the metal, this is important because if you keep grinding for to long in one spot, it will create a lot of heat, which will warp the metal. Be sure not to cut to deep into the metal because you don't want to cut through the frame of the body panel, just the skin.

After you cut the skin of the fender off, line up the new metal cut it about a centimeter above your cut. Then flange the old metal, the best way to do this is to get a pneumatic flanging tool, you can find these very cheap at stores like harbor freight. some of these come with a punch, which is also handy to have. This next step is optional, punch or drill holes in the old metal where you flanged it, after you have these holes line up the metal were you want to weld it, then either clamp the metal in place or have someone hold the metal for you, then fill the holes you made with weld. This will hold the metal better and make it easier to make a bead of weld later on.

After you weld it from behind and on the front, grind the weld on the front down then used bondo or some type of body filler to make the old panel flush with the new one. Then this panel should be ready for primer and then paint.