Checking the fit of the flare to the quarter panel
Lining up the flare and rocker panel and then clamping in place
Tracing the flare outline onto the quarter panel
Area of the quarter panel that will be cut out
Removing the primer with a wire brush wheel along the welding lines
Clamping the bottom edge and the start of cutting
A hacksaw blade was used to cut along the outline of the flare, the resulting cut is about 1/32” which works well for a full penetration MIG weld
As I worked around the flare I used a butt welding jig to hold the joint and tack welded the panels together
The flare is now tacked in place and the old metal has been removed from the original quarter panel
Going around and filling in the welds between the tack welds. This was done in short 1” sections, skipping around, and letting the welds cool to avoid too much warping of the panels
