Well I got the lead out and I did find some rust by the drip rail so I am glad it came out.
Should I just drill the spot welds and plug weld in the new QTR or do I need to do a butt weld? I am planning on using Epoxy over both sides and then filling with Fiberglass filler, No lead, unless you guys convince me otherwise.

BTW these Blair Rotabroach spotweld cutters ROCK, I ordered the Blair "stick lubricant" that should be here tomorrow, this new panel knife is 10 times better than the old air chisel, and doesn't get stuck in the panels :)

I watched a video on this, they spotted the quarter at the roof line and then cut a patch to go over it and welded it in. looked like a really neat repair and eliminated all the filler.

Install it just like GM did. Drill out the welds holding the roof skin to the quarter then just peel the roof skin up a bit. Then use a cut off wheel and grind away the welds holding the quarter on. I do it this way because many time the welds dont always line up.

Plus its easier to control and avoids drilling too far deep damaging the underlaying metal you want to save.

Slide the new quarter under the roof and weld it. Grind the welds flush, hammer the skin back down and weld it. Now you have a solid unit and the risk of not fully welding all three pieces together is removed versus if you tried to weld them all at once...Eric

Thanks Eric. Will Do. I assume you guys all feel that EVerglass filler over epoxy is best since I wont be re leading the seam?

Thanks Eric. Will Do. I assume you guys all feel that EVerglass filler over epoxy is best since I wont be re leading the seam?

Yes, that's fine. I did one of my cars' sailpanels with fibreglass filler in '90 before the hype of epoxy prior to filler and it's fine today. I finished with filler of course. I see MCC actually fills the sails with metal and eliminates filler altogether. Never did it all these years but it is quite an impressive approach. I've never had a comeback with filler nor has anyone I know in the business.

I filled gap with Marson Platinum filler as the void wasn't very big or deep on mine. I have had bad luck with fiberglass filler lifting. I just epoxied the seem once welded and applied the filler. I don't foresee an problems with this.

I filled gap with Marson Platinum filler as the void wasn't very big or deep on mine. I have had bad luck with fiberglass filler lifting. I just epoxied the seem once welded and applied the filler. I don't foresee an problems with this.
Lifting what? Are you talking about the short strand fibre reenforced filler? I forgot to mention another I know has only used regular filler for 30 years and that never failed either. But I'm partial to splitting the filler between the two products.

I could see it IF the hardener was bad or not mixed right, but never seen glass filler lift. But everything is possible.

I use duraglass

http://inlinethumb32.webshots.com/42719/2283859980102553149S600x600Q85.jpg (http://rides.webshots.com/photo/2283859980102553149XMUqMD)

Followed by one coat of metal glaze.

http://inlinethumb37.webshots.com/10660/2924878770102553149S600x600Q85.jpg (http://rides.webshots.com/photo/2924878770102553149QbFqlC)