chevelle

The only major bodywork consisted of replacing the multiple-patched quarter panels. In order to make the work as clean as possible, I replaced the outer wheelhouses and trunk drop-offs at the same time. This eliminated any leftover rust, and helped alignment of the new parts.

    After removing the cancerous areas of the quarter panels, I trimmed along the outer wheelhouse and separated the bad metal from the car.

    The inner wheelhouse lip was then ground smooth, and the new outer was positioned and clamped in place. The new outers alignment with the existing inners was easy - the new panels received from Sherman & Associates fit quite well.

     I then used a trick I learned on-line for perfect butt welding of new skins to existing panels. After using the outer wheelhouses and existing body lines for alignment, I clamped the skin in place at the wheelhouse lip. I then used a thin body saw blade to slice through both the new panel and existing panel. This left a 1/16" gap or so (same width as the body saw blade), which was perfect for filling in with the MIG welder. Using the tip is the MIG, I pushed the new panel flush with the existing quarter on the car, and put in a spot weld. By repeating this process in 4 to 6 inch increments, I was able to follow the periphery of the new skin all around the body, and create a nice flush-mounted repair.

     Although the pics don't show it, the spot welds were continuously connected before bodywork began. Just be sure to weld in different areas of the panel to avoid heat buildup and panel warpage.