Then weld on the new panel. The replacement panel will be slightly larger than the old one so that it can cover the hole left behind. When welding, use all the necessary safety equipment and take proper precautions.
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Chrysler Rust Repair Panels. Next, Schrock prepared to cut the metal that will form the lip inside the wheel opening. He repeated the previous step, placing a piece of flat stock in the wheel opening to trace the shape of the lip. Tape was placed on the drawn line and he cut the metal to shape. This metal strip forming the lip inside the wheel opening bends around the tire, from in front of the wheel opening to above the tire to the back of the fender.
As such, it must be bent, so Schrock begins bending the cut piece of metal at its end to avoid kinks. He works the strip over his knee to the center of the strip to avoid kinking the piece.
He frequently compares its shape to the outer quarter panel it will meet until he is satisfied with the shape. Schrock cuts the sheet metal with the power shears. The remaining patch panel after the excess metal was removed. With the two pieces cut to shape, Schrock was ready to begin pounding the contours around the wheel opening into the outer quarter panel. It will allow him to bend the metal at sharper angles using a duckbill pliers.
For smoother bends, it is not necessary to support the metal with a bar stock guide. At this point, he estimates the shape of the contours around the wheel opening, frequently comparing it to the thin metal templates he formed earlier from the body line.
These templates outlined the shape of the original outer rear quarter panel. Schrock will use these to guide his forming of the new outer rear quarter panel. Note each template is marked with its location. A second, oversized piece of sheet metal stock is placed in the rear fender well to size up the new wheelwell lip. Schrock butts the new metal against the existing inner quarter panel to guide the line he will cut to form the lip inside the rear quarter panel.
To pound the template shape into the outer quarter panel, Schrock uses a body hammer with a convex face to further shape the metal. The convex-faced body hammer also helps keep the sharp bends in the quarter panel, all the while leveling out the panel for a smooth surface. Some bending was required, so he bent the new outer quarter panel by hand to match the lip piece he created. Once the pieces were lined up in the ideal location, Schrock drew a line across both pieces to mark the proper place to tack weld them together with a wire-feed welder.
Schrock used a power shears to cut the sheet metal that will form the lip top metal sheet. Welding the two pieces together can be tricky at the lower part of the fender, due to the size and contours of the metal. Schrock slowly tack welded from the top to the bottom of the fender, bending and hammering the outer quarter panel to match the lip as he worked down from the top of his new patch panel. His tack welds were widely spaced and were intended to simply hold the pieces together until they would be completed wire-feed welded together.
The weld was then grinded smooth, and the new panel was ready to be mounted on the car. A piece of thick flat metal stock is placed along the edge Schrock will begin bending the metal to form the sculpted bends. The thick bar metal stock works well for make sharp bends, but softer bends do not require it.
A second duckbill pliers is used to bend the inner edge of the new quarter panel patch piece. Schrock used a convex body hammer to finish off the edge of the outer quarter panel after initially using the duckbill pliers. Schrock lines up the two metal pieces he fabricated — the outer quarter panel patch and the lip inside the wheelwell — and determines where they should be welded together.
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