How to Replace 65 Mustang Quarter Panel

The 1965 Ford Mustang is a popular restoration candidate. However, after many years on the road, the typical 1965 Mustang will need some rust repair, particularly the rear quarter panels. The quarter panel is the sheet metal panel that covers the area from door to the rear of the car and extends from the base of the rear roof pillar down to the wheel well. The original panel is welded in place and will have to be drilled and cut out before a new panel can be welded in its place.

Difficulty: Challenging

Instructions

Things You'll Need:

• Drill
• Drill bit set
• Wire wheel drill attachment
• Mig welder
• Clamps
• Metal shears
• Body solder kit
• Sandpaper

1. Remove the old rusty or damaged quarter panel by drilling out the spot welds that hold the quarter panel in place with a drill and a sharp drill bit. Use a wire wheel attached to a drill to clean the rust off of all the spot welds so that they will be visible. Use a propane torch to melt the lead out of the seam where the top of the quarter panel and the base of the rear roof pillar meet. Drill out the spot welds that were under the lead-filled seam. Cut the quarter panel in pieces with metal shears or a metal nibbler so that it will be easier to remove.

2. Dry fit the new quarter panel by sliding it under the rear roof pillar. Since every car is different, the new panel may need some tweaking to fit into place. Make sure the gaps at the rear of the door and at the trunk lid are correct. Tack weld the panel into place once it is correctly fit. Mig weld the bottom of the quarter panel to the rocker panel. Mig weld the seam at the top of the quarter panel to the base of the rear roof pillar.

3. Spot weld the seams between the quarter panel and the outer wheel house, the rear tail light panel and at the door jamb. Grind down all welds until they are smooth, but do not remove the welds. Use seam sealer where the quarter panel meets the door jamb and at the trunk lid opening.

4. Refill the seam at the quarter panel and the base of the rear roof pillar with plastic body filler. Use lead in the seam if you wish your restoration to be authentic. Use a file to smooth down the seam and then block-sand, if necessary. The quarter panel is now ready to be primed and painted.

Tips & Warnings

• Before you remove the old quarter panel, make sure your Mustang's doors and rear trunk lid are aligned properly, as they will help you position the new quarter panel.

References

• Mustang Monthly