How to Replace a Nova Quarter Panel

Replacing rusted rear quarter panels on a Chevrolet Nova eliminates rust and dents without using an excessive amount of body filler. The steel replacement panels require an exact fit to ensure the seams from the panel blend into the surrounding area. A misaligned seam will cause a ripple where the panel meets the body. Follow proper procedures to replace a Nova quarter panel to ensure a straight body line that is free of rust and dents.

Instructions

1

Cut around the damaged quarter panel with an air chisel. Leave 3 to 4 inches of quarter panel remaining on the vehicle chassis. Leaving more of the quarter panel in place is preferable to removing too much material.

2

Attach a 60-grit flapper wheel to an angle grinder. Sand the flanges holding the damaged quarter panel to the vehicle chassis with the flapper wheel. Continue cleaning until you can see the spot welds holding the panel in place.

3

Drill through each spot weld with a drill motor and 1/4-inch drill bit.

4

Slide the end of a chisel between the flange of the damaged panel and the body of the Nova. Hit the end of the chisel with a hammer to break the bond remaining around the spot welds. Pull the remaining section of the damaged quarter panel from the vehicle's body.

5

Set a replacement quarter panel against the side of the body. Align the ends of the quarter panel with the areas of the Nova body contacting the quarter panel.

6

Turn on a MIG welder. Set the MIG welder heat and wire speed settings with the weld thin-gauge quarter panel. Test the weld settings on the removed section of quarter panel. Adjust the settings as needed.

7

Place one tack weld at each spot weld you drilled from the old quarter panel. Tack weld the top edges of the replacement quarter panel to A-pillars coming down along the Nova's rear window.

8

Weld the seam between the replacement panel and the A-pillar. Weld the reaming seams between the contact points of the replacement panel and the Nova body. Allow the welds to cool for 30 minutes to one hour.

9

Blend the welds located on the replacement quarter panel seams into the Nova body by slowly working along each weld with the 60-grit flapper wheel and angle grinder.

10

Coat the blended seams with body filler. Allow the body filler to cure for 15 to 20 minutes.

11

Sand the body filler with 100-grit sandpaper to blend the quarter panel to the Nova body.

12

Spray primer over the replaced quarter panel. Allow the primer to dry. Wet sand the primer with 400-grit sandpaper. Rinse the quarter panel.

13

Spray paint the sanded primer. Allow the paint to dry.

14

Attach a buffing pad to a buffer. Coat the pad with buffing compound. Buff the quarter panel and surrounding area to blend the paint into the surrounding area.