How to Replace Jeep Body Panels

The more off-roading you do in your Jeep Wrangler, the bigger the chance that a body panel will suffer--anything from small dents to a complete crushing.


If you're serious about auto repair and experienced, it's something you can do. Otherwise, leave it to a professional to do, as it's out of the league of most shade-tree mechanics.

Things You'll Need

  • Sawzall
  • Vise-Grips
  • Spot-weld drill
  • Welding equipment
  • Wrenches
  • Sockets
  • Remove seats and rollbars, remembering to release any wiring that may be attached.

  • Remove spot welds with a spot-weld-removal tool that can be attached to a regular drill. In places where the spot welds are inaccessible for the tool, use a Sawzall to cut through the welds.

  • Use the Sawzall to cut through the welds where side panel meets the cowl. Take off the fenders prior to removing the body panels. This will leave a piece of the body panel under the cowl, for which removal is easier with the bigger part of the panel out of the way.

  • Remove the body panel brace with a welding torch, a cutting disc or a sharp chisel. If you use the chisel, be careful not to cut through the floorboard.

  • Pry off the panel once all of the welds are cut through. Some brackets you didn't see may be still holding the panel on, so go slowly as you pry. This should allow the panel to slide down (use two people to do this part to avoid damaging other parts).

  • Prepare the body for the new panel. Straighten all the flanges to allow a firm fit of the steel, which prevents warping of the steel panel when it's welded.

  • Cut the emergency bracket off the old panel. After cutting off the bracket off the old panel, mark the correct location on the new panel and weld.

  • Put the new panel in place for welding, using Vise-Grips to hold it in place. A wire-feeder welder makes welding easier. To avoid warping of the metal, weld in one spot, then weld some distance away to let the first weld cool. Keep Vise-Grips in place until all welds are cooled.

  • Replace all interior parts, then paint the panel to match the rest of the exterior