1. Preparation:
- Remove the rear bumper, tail lights, gas tank, and any other components that may obstruct access to the quarter panel.
- Disconnect the fuel line and any electrical connections in the area.
2. Remove Old Quarter Panel:
- Using an angle grinder or a spot weld cutter, carefully cut along the spot welds that attach the old quarter panel to the body. Be cautious not to damage the surrounding areas.
- Once the spot welds are cut, gently pry the old quarter panel away from the body using pry bars or a crowbar.
3. Clean the Area:
- Clean the area where the old quarter panel was removed to prepare for welding. Remove all rust, debris, and old sealant.
4. Fit the New Quarter Panel:
- Place the new quarter panel in position, aligning it with the body and ensuring that the gaps between the panel and the adjacent panels are consistent. Use clamps to temporarily hold it in place.
- Check the alignment of the quarter panel with the door gap and trunk opening to ensure proper fitment. Make necessary adjustments.
5. Spot Welding:
- Start spot welding the new quarter panel to the body along the spot weld flange. Use a spot welder or a MIG welder with a low heat setting to create small tack welds. Work your way around the entire panel, welding in short intervals to avoid overheating the metal.
6. Welding:
- Continue welding the quarter panel to the body using a MIG welder. Weld along the spot welds you created earlier, creating continuous welds. Be sure to weld all the way to the bottom of the quarter panel.
- Finish the welds by grinding down any high spots or uneven areas.
7. Seam Sealer and Body Filler:
- Apply seam sealer to all the welded seams to prevent water from entering the seams.
- Use auto body filler to smooth out any imperfections or gaps between the new quarter panel and the adjacent panels. Sand the body filler to create a smooth surface.
8. Paint and Reassembly:
- Once the bodywork is complete, prime the new quarter panel and the surrounding area.
- Paint the quarter panel and the rest of the car to match the original color.
- Reinstall the components that were removed during disassembly, including the rear bumper, tail lights, gas tank, and any electrical connections.
Note:
- This process requires welding skills and proper safety equipment. If you are not experienced with welding, it's best to seek professional help from a qualified auto body shop.
- Refer to the vehicle-specific repair manual for detailed information and measurements related to your 1965 Chevy II Nova.
