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Diving into the deep end, replacing rear quarters on a 71 Cutlass Convertible
I am going to try and replace my quarter panels. I have never tried to do anything this involved before. But everybody has a first time. I will add pics in the near future. I just got some patch panels cut and sent to me from a rust free car. I am hoping to get one side done before spring. I can weld but not great. I have an old fender that I am going to practice on before starting on the quarters.
My plans
1 Clean garage so i have as much room as possible
2 Drop gas tank and take off rear bumper
3 Start sanding to find out where all the rust is
4 Cut out and replace the panel
5 Try and avoid to many MAW
Any pointers? Am I missing something?
My biggest problem is that I sometimes rush and get in a hurry. I need to force myself to take my time. The car is a driver. I am hoping that I might inspire someone else to try. Hope I don't drown.
Definitely interested in following along any documentation/photos you share of your project. I'll be doing similar repairs to my '71 at some point in the future.
You may want to consider replacing the entire quarter panel since they reproduce the full panel. The reason that i suggest this is that you may find that "chasing" patch replacement may be more involved than you think and at the end of the day it could take longer and the result not as good as full replacement. I have welded the partial quarter on a hardtop and it was alot of work. They do not make the full quarter for the hardtop or that would be the route i would have taken.
I really did not want to do the entire quarter. It is only really bad around the wheel well and behind the wheel. The patch panels I got were cut from another car. It may end up to be more work but it is what I want and try and do. First part cleaning garage will be done this weekend, I hope.
Olsmaniac:
I'm knee deep in quarter replacement as well and curious to know how much of the original door jamb you kept; or did you replace the jamb as well? Any pics of the jamb area showing where you cut? Thanks!
Rodney
I removed original quarter wrap around to door jam as the replacement came with that and just duplicated the factory setup there. All the picts I have were in thread posted above I mean the link to the build.
Larry, just wondering how it's going with the patch panels. I think I'm in the same spot as you. Had a small rust spot behind each rear wheel, went poking around, and now I've got a 5x6" piece cut from each side. I don't have replacements though, going to try and make my own. How is the outer wheelhouse where it joins with the skin? I'm going to have to replace a little of that too.
I'm new to body work, as well. Just learning to MIG weld. My welds are ugly but I'm learning to keep the metal cool.......very cool. Lol.
Haven't done anything yet. All my plans were foiled by a list of honey-dos for the wife. Now with work picking up it may be fall before I get started again. To be fair most of the list of honey-does really need to be done. I just would have done them in a different order.
Yeah, I guess that stuff has to get done. Homeownership can be a full time job. I'm on spring break this week (but it's snowing like crazy) so i get to do what I want. Making this patch panel wasn't too hard. The hard part was getting the hole cut right. Dremel or angle grinder. I wish there was something in-between
Olsmaniac:
I'm knee deep in quarter replacement as well and curious to know how much of the original door jamb you kept; or did you replace the jamb as well? Any pics of the jamb area showing where you cut? Thanks!
Rodney
Here's a pic of my progress.
I see this in my near future. I have been offered the right quarter as a NOS part for around 2K, If I could get a left and right for around 3K I'd probably do it
Finally getting started. Cleaned out the trunk. When I got everything out, it is more rusty than I thought. Will be doing the trunk floor also. Got the bumper and trunk lid off. Side marker out.
Hope to drop the gas tank tomorrow. Pics in the next couple of days.
Larry and others w pics in this thread what are you using to cut the quarters off? When I did the floors in my car I started w a very thin cut off wheel ,but it was to imprecise, loud, dirty etc for working in the car. I switched to an air saw w short blade and found it easier to use and less messy, but I wonder if there's a better tool?
Larry and others w pics in this thread what are you using to cut the quarters off? When I did the floors in my car I started w a very thin cut off wheel ,but it was to imprecise, loud, dirty etc for working in the car. I switched to an air saw w short blade and found it easier to use and less messy, but I wonder if there's a better tool?
Not sure what I will be using. Probably a combination of things dremel, angel grinder and a air cut off wheel, and a saw with a short blade.
Got everything ready to start removing metal. Dropped the gas tank but forgot to disconnect the ground. If this is my worst mistake I will be very happy. Had trouble with getting the rear seat out. The bracket holding the wire on the passenger side was bent and couldn't get it out. At some point the rear window got busted because I found at lot of busted glass. Nothing interesting under the seat.
Larry and others w pics in this thread what are you using to cut the quarters off?
So far I've used a thin 4-1/2" cut-off disc on my grinder for most of the cuts and (don't laugh) a sawzall to finish up in tight corners where the grinder wouldn't fit. Cutting with the cut-off wheel is very dirty and all the sparks require alot of extra caution, but the cuts go pretty quickly.
ok thanks for the info guys, the cutoff wheel was quick but working under the dash w the sparks etc was to much, w the air saw (like a mini sawzall) it was easier and cleaner plus i could get closer to it without worrying about the flying debris
heres the saw i used pretty happy w it thin cut (proBably thinner than the thinnest cutoff wheel) easily as fast and less debris and no sparks)
When i replaced the one on my 67, i used Harbor Freight spot weld cutters, they are cheap and work good. There were approx 150 spot welds. I cut it at the bottom of the sail panel just below the holes for the vinyl top trim. I had a nice used original panel, so it fell into place pretty good. Different year i know but pretty much the same procedure. Just behind the door i cut it at the bottom from the door jamb to the wheel well, leaving about an inch above the seam at the rocker panel. It was alot easier to cut the spot welds fender to rocker with the fender off as opposed to trying to cut them through the window access from the inside. It was my first time to replace a quarter, not difficult just time consuming. I actually enjoyed it, learning how.
Larry and others w pics in this thread what are you using to cut the quarters off? When I did the floors in my car I started w a very thin cut off wheel ,but it was to imprecise, loud, dirty etc for working in the car. I switched to an air saw w short blade and found it easier to use and less messy, but I wonder if there's a better tool?
I used a cheap Harbor Freight nibbler. It works like a dream but it can get away from you fast so be patient and if possible use a guide/fence to keep it in place. Cutting disc work well to but be patient once again. Basically whatever tool you use you have to have a steady hand or make it steady somehow.
These are recent pics from my job. I also used the nibbler to final size the patch panel. Just cut down my fence and attached it to the back side of the panel and held it in place with simple C clamps. The Clecos are a nice addition for a one man band. I also used a HF panel flanging tool and spot weld hole make on this.
Been able to do a little over the holidays. It is moving slowly, lots of spot welds and taking my time so I don't do anything stupid. I have to force myself to take it slow, my biggest problem is rushing. This is the biggest chunk of the elephant by far.
Cool. I really enjoyed the little bit of body work I did. Mostly because body work has always scared the crap outta' me. It took the mystery out of it. Well, at least SOME of the mystery, lol.
If your going to be welding that seam in the middle of the quarter, take it very slow as too much heat will spread into the surrounding area and warp the panel. Then you have that problem to deal with. Be patient and weld only about 1/2 inch then cool the area, move to the opposite end and do the same. The advantage of replacing the whole quarter is that the welds are all on the outer perimeter of the panel and less likely to warp, and a lot less body filler. There is some kind of metal adhesive that apparently works very well, another member used it, ?Copper Cutlass or Oldstata? Sorry I cant remember who.
good luck
Steve
If your going to be welding that seam in the middle of the quarter, take it very slow as too much heat will spread into the surrounding area and warp the panel. Then you have that problem to deal with. Be patient and weld only about 1/2 inch then cool the area, move to the opposite end and do the same. The advantage of replacing the whole quarter is that the welds are all on the outer perimeter of the panel and less likely to warp, and a lot less body
X2, that seam could show up in the paint as a shadow, better to fit the panel to the body lines.
January 3rd, 2017, 06:30 PM
