Replacement Sequence

[NightDiver]

I need some advice on what order to replace panels damaged in a collision. If the trunk pan, the tail light panel, and a rear quarter all need to be replaced, what would be the best method of replacing them and what additional bracing, clamping, etc. should I use in the process?

[Evldoer]

It would be nice to know what kind of car this needs to be done on. If it was my project, I would start by figuring out if you need a whole 1 piece trunk pan or just a section. Some cars have trunk pans availabe as a 3 piece set, or 1 full pan. If its a 1 piece you go with, you will have to take the tail light panel off, and maybe even the quarter to get the pan in there without cuting it. you can cut off the quarter and the tail panel. Get the new pan in there, and tack it in. I like to use cleco fasteners, they are cheap, and work great. then get your quarter tacked on. then fit your tail panel.
If your trunk lid is not damaged, I like to leave it on the hinges through this process, so you can easily check the fitment of the rest of your penels.
When you are tacking panels on, take your time and pay close attention to how everything fits. Remember that as you tack weld, the panels will move around some, so you have to keep checking things. Once everythjing is tacked in place, and the fitment is good with the door to quarter, and trunk lid to quarter to tail panel, start finish welding it. go SLOW! To fast and you will put to much heat in the panels and it will warp, and create waves. Same thing with grinding, to much heat and it will warp on you.
Depending on the car, be sure to test fit the tail lights to it before you finish welding it all.
Take your time and pay attention to the details. When the quarter is off, clean everything up underneath, and seal the metal with epoxy primer.
Remember to pick up some weld-through primer and use it on the panels. Napa carrys it, and it works well.
Now get going you have some work to do!!

[NightDiver]

Oops, I thought I put the car in my last post... This would be on a 69 Camaro. Due to the damage and corrosion, Im looking at going with a full trunk pan just to make sure it will be large enough. I will need to replace the trunk lid due to rust, but I planned on keeping it installed, as you mentioned, to check against quarter fit.

Thanks for the information, I was having trouble figuring out if it would be better to fit the quarter in first, ensuring proper position with the door and trunk and then installing the tail light panel, or installing the tail light panel first to ensure it was level and then using it to fit the quarter in along with the trunk and door.

[ssealeycpa]

I agree with Evldoer. Since this is a Camaro, keep in mind that a truck floor is welded to the stamped frame rails, so all of those spot welds will need to drilled. Get your car leveled on jackstands based on factory measurements (do a seach on threads)first and cut the quarters a little at a time. If the door openings are good, I would graft in a Skin on the quarter if you are able to (if rust damage isn't to bad). You are probably going to need outer wheelhouses and truck floor extensions.

Good Luck!

[shep]

If your replacing the trunk lid wouldn't you want to fit the new panels to it? Since it wont fit exactly like the old one.

[NightDiver]

If your replacing the trunk lid wouldn't you want to fit the new panels to it? Since it wont fit exactly like the old one.
Yes, and that's one of the reasons I am having trouble figuring out what would be the most efficient order of replacement... With 4 adjacent pieces being replaced, which should be replaced first and then used as a fitment reference for the others? As the moment Im thinking trunk pan, tail light panel, quarter, then trunk lid...

[Evldoer]

Thats why I suggested using clecos. That way you can fit all the panels to the car, instead of tacking them, you use the clecos, and if something doesnt fit correctly, you can pull some clecos, and move the panel. then reinstall the clecos by drilling some new 1/8" holes and poping the clecoes back in. They also help hold everything in place when welding.

[NightDiver]

Ok, I guess that is where the confusion was coming from. I was trying to figure out which order to completely weld in each panel when I should actually fit everything using clamps, then tack once fitment is as good as I can get it. Then, once tacking is complete and fitment is satisfactory, go back and final weld... That is if I understand you correctly...

[Evldoer]

Yes, thats the way to do it, IMHO. Check ebay for the clecos, pretty much the cheapest place for them. Once you use them, you will understand why they work so well. Nobody likes cutting a freshly welded panel off just to move it a little bit.
http://cgi.ebay.com/WEDGE-LOCK-CLECO-PLIERS-AIRCRAFT-RACING-CLAMPS-_W0QQcmdZViewItemQQhashZitem2c5eb77861QQitemZ19056 7643233QQptZBIQ5fToolQ5fWorkQ5fHolding

http://cgi.ebay.com/ebaymotors/Cleco-50pc-set-1-8-copper-Clecos-all-NEW-605-/260732562329?pt=Motors_Automotive_Tools&hash=item3cb4df2b99