How to Install Autobody Repair Panels

Rust, when left untreated, can completely destroy the larger body panels of any vehicle. If you live near a body of salt water, or in colder climates where the roads are frequently coated with salt due to ice and snow, you have seen what rust can do to vehicles. To make matters worse, some body shops try to repair these huge rust holes with improperly mixed and poorly applied panel filler. The repair can look almost as bad as the rusty holes. Replacing the entire body panel is the quickest, best, most permanent way to repair extensive vehicle rust.

Instructions

1

Clamp the replacement panel onto the panel to be removed. Align the new panel exactly on top of the existing panel, paying attention to any grooves or other body features. You are about to make your cutting line on the existing vehicle body. Draw a line using a marker along the edge of the clamped panel onto the vehicle body.

2




Mark a wide, bold line that can be followed while cutting.

Unclamp and remove the replacement panel from the old, rusty one. Make a mark inch below the line you just traced in using the new panel. Draw in the line, the actual cutting line, parallel to the top line. You will need this inch for crimping the new panel into place.

3

Put on eye protection, and cut away the old panel using a nibbler/metal cutter. Take your time and use a steady hand to stay on the line, making a straight, clean cut. Locate and grind to expose any spot welds that may still be holding the rusty panel onto the body. Use a drill and bit to remove them.

4




Proper blending in of the paint renders the new part undetectable.

Use the body grinder to grind paint off down to the metal 4 inches above the cut you made earlier. Create a lip or flange along the cut edge you just grinded the paint from inch wide using a joggle or crimper. Keep it straight as possible and aligned to where the new panel will be mounted.

5

Place the new panel into position along the newly made flange. Use temporary fasteners and not metal screws to hold it into place temporarily. Remove the primer 2 inches from where the new panel will be welded into place.

6




Welding that can not be visually detected is good welding.

Use stitch welds as opposed to spot welds along the length of the newly installed panel. Make 1-inch welds 8 inches apart, and this will limit warping and the waves of spot welds. Use the grinder to remove the excess weld material, creating a slick painting surface.

7

Add as little body filler as possible. Sand, prime and paint the new panel. Blend in the paint to match evenly. If the paint is a difficult match, paint the entire section of the vehicle to avoid repair lines.