DanHS

Ok, I need to repair the mashed quarter panel on my '89 hatchback, the unibody structure behind seems sound, just the skin and part of the fenderwell are damaged. My plan is to cut out the old fender along the seam, and then cut across where the quarter window goes. On the donor car I'd cut the sheetmetal along the same seam, and a little further up the panel where the window is, so when the new panel is placed on the car, there is an overlap. The panel will be tacked in place, and I'll cut through the overlap so the sheetmetal is perfectly aligned. Then that will be tack welded, ground, and filed smooth. Here's a pic of what I'm planning:
http://i8.photobucket.com/albums/a22...nderrepair.jpg

I'm not looking for utter 100% perfection, just decent, this car is just a driver, nothing for show. Any suggestions and info? I've got two auto body guys telling me there's a seam between the roof and quarter panel, and I should drill out all the tack welds and replace the entire quarter, but I can't find any seam anywhere, and that'll be three times the cutting and welding, and then trying to properly finish the curve rather than a smooth surface. Is there some magical hidden seam I can't see or is it one piece like I thought?

spudz

that damage is fixable without quarter replacement... I wouldn't cut it out.. I mean you can but its faster and I think you will have a better result straighting that dent.

stang8689

you need a new quarter, you are on ther right track. Just do it like you have plnaned, I would use an extra piece where you weld the sail panel toghther, I mean behind the 2 for extra weld support

aode08

take your time,

uedlose

you should put that Quarter in all the wayto the front and not cut it in the middle. there is a seam at the roof line down about 3in iswhere they put it together. if you cut that thing in the middle you might as well just fix what you got. Trust me I didbody and paint work for 15 years. for a living. the seam you are looking for is leaded in.

ddeaton66

The auto body people are telling you right. IF you replace metal, replace the whole quarter it's actually easier and usually less work in the long run, find the seam and the spots at the door frame. It'll be easier to make/keep straight. If you pull it then just take your time and get it as straight as possible. The thinner the mud the bettter.

Luck

5.0stanger

You can buy a re-pop from cj pony parts for about $150 too BTW

I also would remove the window to save on bodywork. Then you can cut under the glass. I would also use a whole panel instead of cuttimg it in 2, just go all the way to the door. Once you start welding it back together, it will make a mess out the sheet metal.

DanHS

Alright, I found the seam with a magnet, it's completely invisible otherwise, a very perfect job. A guy on my Jeep forum says when he worked at a Ford dealership, he learned that they were actually leaded by machine, which is something I'd like to see.

Anyways I need to know the best way of taking it apart, can I reach the spot welds under the seam from behind (inside the car), or will the unibody structure be in my way?
And is this a good filler to use after welding on the new panel: http://www.tcpglobal.com/autobodydep...emno=USC+14060