How to Weld Quarter Panels

Road salt and moisture cause the rear quarter panels of older vehicles to rust. When left unchecked, the rust will grow into a hole with the area around the hole becoming thin. Cutting the rear quarter panel from the vehicle and replacing it with a new body panel eliminates the rust. The new quarter panel welds in place of the cut-out panel. Correctly aligning and fitting the new quarter panel will ensure a professional repair.

Things You'll Need

  • Wire wheel
  • Angle grinder
  • .023 diameter ER70S-6 MIG wire
  • 75/25 shielding gas
  • MIG welder
  • Welding hood
  • Secure a wire wheel to the angle grinder.

  • Clean paint and rust from the area above the cut you made to remove the old quarter panel with the wire wheel. Clean the primer from the edge of the new quarter panel to weld to the vehicle with the wire wheel. Continue cleaning both pieces until you expose clean metal.

  • Install a spool of .023 diameter ER70S-6 MIG wire and a bottle of 75/25 shielding gas to a MIG welder.

  • Set the new quarter panel in place. Align the body lines of the quarter panel with the vehicle door and the seam of the trunk lid.

  • Put on a welding hood. Align the tip of the MIG welder gun with the seam between the vehicle body and the edge of the new quarter panel. Press the trigger of the MIG gun to place a tack weld on the seam. Move down 2 inches and place a second tack weld. Place an additional tack weld every two inches until you reach the opposite end of the quarter panel.

  • Align the tip of the MIG gun with one end of the seam between the new quarter panel and the vehicle body.

  • Lower your welding hood. Press the trigger of the MIG gun. Move the MIG gun 1/8 inch and stop for the count of one. Move another 1/8 inch and count to one. Repeat until you have the seam welded.

  • Allow the weld to cool before grinding and finishing the welded seam.