I am getting ready to weld in some new lower quarter patch pannels and have heard of many tools used to remove the old metal from air jig saw with a metal blade, to a plasma cutter to a cut off wheel on a angle grinder or air die grinder. I have access to all these tools which one will work best? I saw a interesting article on here a while back with pics someone had posted of a guy clamping the new patch over the body and then using a cut off wheel on a air die grinder to cut the new patch as well as the old metal at the same time while stopping to tack weld every few inches and cutting at a angle to make the cut thin. Anybody done this? What's the easiest best method?

I use a cut off wheel with a 1/32 disc. I have not clamped the two panels together and cut as you described, however, I can see that working. Just be sure you have the patch trimed like you want it. The cut off wheel doesn't seem to distort the metal like an airchisel, saw or other tools. Just my opinion. Hope this helps.

The fit, clamp, cut then weld method works best for me. I use a piece of wire to pull the excess metal from the backside of inaccesable areas as I cut and weld the panel flush. I prefer using an air body saw-(no warpage, no heat, thin cut, blades are cheap, no sparks, cuts curves easily compared to a cut off wheel) I'm sure you could use an elctric jig saw with the same basic results. The keys to a good job are take your time and fit the panel well-the patch should fit without contortion-sp?, cut only 4-6 inches at a time and follow up with welding. The pieces should align easily if fit well. Take your time weld slow with plenty of cool time as you go to avoid warpage. If the panels start to warp work it back with hammer and dolly before you continue on. Grind your welds down slowly skipping around to avoid heat generated warpage. Good Luck-You can do it! graemlins/thumbsup.gif

Not sure but you may be referring to my pics of an 80% quarter installation.
HERE (http://f1.pg.photos.yahoo.com/ph/ochrisl/album?.dir=/1970+Chevelle-80%25+quarter+left+side&.src=ph&store=&prodid=&.done=http%3a//f1.pg.photos.yahoo.com/ochrisl)

Hey, that looks exactly how I do it. Nice job. I usually put a screw every six to eight inches along the horizontal mid panel seam to keep it from moving around and zip them out and buzz the holes as I go.

Thanks, i did have screws in it also. It works well, just be sure not to weld the new panel to the old strip behind it.I did that before and it can be a pain to get undone. graemlins/clonk.gif

Dang,I learned something new tonite. :cool: I have to remember that when I do my wagon ;)

graemlins/waving.gif
Rick

I had great luck cutting with a air nibbler that I got at Northern or Harbor freight ($30-$40) it allows you to round corners with ease. The down side for me was that it leaves little metal cuttings in the shape of a CCCCCCCCCCCCCCCCCC that are fun to clean up
good luck!! graemlins/thumbsup.gif