I have a question about welding on a quarter panel. We will be welding on a panel as soon as I get my welding practice back. We have a flanging tool and will be flanging the old fender, but I am not clear on how close to put the panels. Do the go as close as possible so they resemble a butt weld or do we leave a gap so we can build up some weld. I am going to be using a wire feed, flux core welder. I don't have access to a true mig welder with a gas bottle.

The flux-core welders build a little more heat so you have to be carefull to prevent warpage. You don't really need a full weld on the seams. Once you tack it into position, do some 1/4" long beads. Alternate areas and cool down well between welds. After that you can get some 3M body adhesive and fill the remaining gaps. grind smooth and fill.
I always leave as little gap as possible. Flange the old metal and leave the new panel straight. Make sure that the flanged surface will leave the new panel flush with the old. Some flange tools make too much of a bend and create an un-even surface when done. Just check it to make sure.

[This message has been edited by Jimmy P (edited 07-26-2001).]

Use the new panel as a template to mark the old one for the cut. After you have a line drawn right where the new panel ends on the old panel, make another line about 3/8" away on the "inside" of the first mark. In other words, make a mark that will leave the cut on the old quarter about 3/8" LESS than the new quarter will cover. Make a test on a piece of sheet metal to see how deep your flanging tool goes to be sure.
You will then flange the old panel (or it may be easier to flange the new panel) so that the it will slip under that 3/8" extra metal you left on the old quarter.

BIG TIPS: Test fit it a NUMBER of times before you cut.

You can clamp or use little 1/8" sheet metal screws to hold the panel, you want to hold it on exactly as it will be when you will be welding it.

Take your time, be sure ALL areas fit well, like in the wheel well (if you are replacing that area) it is particularly tough.

After you mark the second mark, put some large arrows so even a damn fool wouldn't cut the wrong line. Take this from a damn fool http://www.chevelles.com/forum/eek.gif

Clean the metal VERY WELL where you are going to weld. Both sides about 1/4" from the weld at the very least. This may or may not be needed, but with the flux core wire and no gas, I think it is best.
Good luck

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1965 Buick Gran Sport Convertible
1965 Buick Skylark H/T
"Fan of most anything that moves human beings"

[This message has been edited by MARTINSR (edited 07-26-2001).]

Thanks for the advice. Its nice to have somewhere to go and ask questions without being treated like an idiot for not knowing.

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