#3 Gray 62 bodywork and paint (1 Viewer)

kelly saad

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Lower door skin patch panels almost done. I need to make a few more to test my templates but it’s close. In this photo, you can see existing bodywork where they drilled holes to use a dent puller, but didn’t actually pull the dent. :alien: So I had to use a hammer and dolly, it’s good now. It had probably 1/2” thick filler in the dent.
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kelly saad

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looking very good now. A new Hypertherm plasma cutter sure does increase motivation :D :bounce:

Now, on to the tailgate, hatch and cowl patch panels. Once they are all worked out with accurate templates, then I will build serval sets for at least 5 vehicles. We have ordered quarter panels, so as of now I will not spend time on that, however I will make my own quarter patch panels too eventually.

I should have some exciting photos soon. there has been a lull in the visible progression latey, so I haven’t posted anything. Lots happening but nothing new to show.
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GLTHFJ60

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Out of curiosity, why did you chose to create the lap joint in the middle of the panel, as opposed to using a panel alignment clamp and butt-welding the two pieces together?
 

kelly saad

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Out of curiosity, why did you chose to create the lap joint in the middle of the panel, as opposed to using a panel alignment clamp and butt-welding the two pieces together?
I use a pneumatic flange tool, so it is a lap but the new panel will lay in flush. I prefer to use the flange tool on larger areas if I can. Sometimes I cannot get the tool in tight places, so I will use a butt joint then.
 
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kelly saad

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Hi, Looking good. Whose aftermarket panels are you using ? Mike
I am using Wolf out of Canada. The lower section below the body line is all I use. The body lines do not match or line up at all, and are not even usable. So, I cut the lower part off that I need and the rest is scrap. I am not trying to speak negatively about someone's product, but that is what I have encountered. It works out, and I am thankful to have them available. It will be nice to just have my own panels on the shelf soon.
 

kelly saad

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Quarter panel time! They finally arrived yesterday. Stripped everything to bare metal the last 2 days. Today I drilled all the spot welds and raised the vehicle on jack stands. Tomorrow I will cut off the old quarters and other rust spots/holes.

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kelly saad

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After spending quite a while on straightening the upper section of the quarter panel with pry bars, hammer and everything else, it finally looks pretty straight. Is was caved in all around the gas door and the whole back really. The body line was smashed in about 1/2”, so that was fun with all the gas lines in the way.

I finally cut the old quarter off. You can see where the rust had begun, but hadn’t shown itself yet on the outside. I know, why did I cut the old quarter off in such an odd shape?? I can’t use the whole quarter because the body line above the wheel is completely off. So I put the seam through the body line in the pocket where it curves upward. I really wish I could use the whole quarter panel. 😡

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kelly saad

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So, these quarter panels do not fit right in several ways. At the lower corner of the wheel opening, the factory quarter flares outward, these do not. So I have made a cardboard template for where I need to cut the inner fender and move it inward so that it will fit. Notice the gap in the red circle, that is how far it is from fitting correctly. It’s still good that there are available quarters, even if you have to fabricate them to fit. I guess.

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kelly saad

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Steps backwards. Alignment of the quarter panel in the front, where the body like meets the door Doesn’t line up by 1/4”(see photo attached). Due to damage on the original quarter panel, I needed to use the lower line where it rolls into the full body line. My seam inside there would surely be a bear, but that’s ok because it would have minimal filler. I measured first and it looked very close. Once I cut the scrap end off, the lines were off. Not happy. If anyone buys these panels, just be aware that they are not ready to install. There will be fabrication and you cannot use the body lines they rolled into the panels without more fabrication. Only realistically plan to use the section below the body line for rust repair, and then you will only need to rework the lower inner fender well to fit them. For the Price of $250 each, these should not require fabrication of this level. I need to make my own panels ASAP.

I’m pulling this panel off, flattening out the last 10” and running it through the bead roller to blend the body line into where it should be. Lame.

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kelly saad

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Same deal on the drivers side. Hidden rust. You can see on the pics I cut off, it had a small rust hole but the rust was growing in both directions. The lower section was rusty also, but no evidence of it on the exterior. Inner fender has a good amount of rust too. All hidden, and that is why I push for new panels to be replaced.

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