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Weld a new near side panel on a ford transit or a data sheet with sizes or any relevent infomation

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Buy a quarter panel from a junk yard that you want to replace tell the junk yard where you need it cut and tell them all of it that you need then using a pair of nibblers cut out the area that you want to replace. To do this use a measuring tape to measure the area to cut out. Next get some 3/4 masking tape and run the tape along the lines that you want to cut. test cut a piece of metal to see how much the nibbler cuts out and how jagged it leaves the cut and figure this into what you need to cut from the piece from the junk yard. once it is taped off remove bumper, and any wires that might run threw the holes on the panel also remove fuel tank hose if it's in the panel you are replacing. Once its cut remeasure the 1/4 panel and grind any spots that might be to long then match the parts together. ON THE INSIDE OF THE PANNEL WHERE YOU CAN'T SEE IT WELD SOME TABS (Spot Weld) 3 or 4 tabs that will help you line up the two pieces together then slide it in place get one end lined up and a space of the wire you will use to weld it together once it is all lined up pull tape off and use a grinder or wire wheel to remove paint away from the area to be welded by 1 inch. Next start welding it together be careful not to weld one side more than another or yo will get warp age, also don;t let it get to hot. take your time welding it together be sure to get a solid weld be sure all holes that have to be lined up line up. after welding it together then grind it flat and used bondo to fill in and smooth out the welded edge prep with 2 part epoxy primer spray the bare metal and blend into the paint, this will show you if you have any areas to work on. THIS IS NOT A EASY JOB BUT CAN BE DONE. I have cut two cars in half and have welded then together and they were stronger than when they were new. but this requires knowledge of windshield repair and wheel alignment. good luck and if you need more help let me know so I can help you.

Posted on Nov 25, 2009

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