Quote:

Cutting an old quarter panel up is easier of course, but you probably can't find one for a reasonable price. 4speeds makes a good point about the contour of the wheel opening. This is how I make them.
-Make a cardboard template of the wheel opening before you cut the rusted piece out.
-Cut out the rust....straight lines are easier to patch.
-Cut your patch.......make it lots bigger than the hole, bend the lip
-Clamp it on the car in whatever position is required to maintain the contour of the wheel opening.
-With the patch clamped in position, reach in behind with a pencil and trace the hole opening onto the patch.
-Remove the patch and cut along the pencil line.
-Tack and weld.

Take your time and remember......you can't make it worse.

-jr




Instead of cutting along the line you made from the inside of the wheel well, take a drimmel tool with a small cut-off wheel and score along that line ever so lightly. After you've score it, you can bend it around to create the inner lip. After you have it tacked in place you can trim off any excess from your fold from inside the wheel well.
My experience is: You should not cut out any old metal until you have made your patch.

Rob