Warpage
Use the edge step down tool on your existing quarter panel. This gives a place to set the new quarter panel down into and gives the weld area way more strength to keep it from warping the rest of the already straight quarter panel.
@ragtopfury used the stepping edge tool on his Dodge Ram Truck box side repair panel job. Turned out beautiful, now freshly painted red.
The owner being a novice welder, I would recommend tack welding it every half inch grind the high spots off the tack welds without undercutting them.
Then seal the finished joint with a coat of water proof "Duroglas" by USC company, then go to your bondo finishing. The joint will be plenty strong and it is up high enough so water is not going to get into the joint on the inside.
The trouble with welding it solid is extream heat going into it and warping the whole panel, and an aweful lot of grinding to get it cleaned up for bondo.
Being a novice welder you can pretty much guarantee that you are not going to get it 100% sealed by welding it solid anyway, there is always going to be pinholes in your welds.
You can screw your new lap joint together with small sheet metal screws about 4" apart to hold your panels together and straight before and during your tack welding. Then jump around with your tack welding and allow things to cool as you go, can assist with an air blower after each tack weld to cool it.
Less heat, less warpage, held firmly in place = less warpage.
Good Luck on your project, you will be an expert when finished.
Use the edge step down tool on your existing quarter panel. This gives a place to set the new quarter panel down into and gives the weld area way more strength to keep it from warping the rest of the already straight quarter panel.
@ragtopfury used the stepping edge tool on his Dodge Ram Truck box side repair panel job. Turned out beautiful, now freshly painted red.
The owner being a novice welder, I would recommend tack welding it every half inch grind the high spots off the tack welds without undercutting them.
Then seal the finished joint with a coat of water proof "Duroglas" by USC company, then go to your bondo finishing. The joint will be plenty strong and it is up high enough so water is not going to get into the joint on the inside.
The trouble with welding it solid is extream heat going into it and warping the whole panel, and an aweful lot of grinding to get it cleaned up for bondo.
Being a novice welder you can pretty much guarantee that you are not going to get it 100% sealed by welding it solid anyway, there is always going to be pinholes in your welds.
You can screw your new lap joint together with small sheet metal screws about 4" apart to hold your panels together and straight before and during your tack welding. Then jump around with your tack welding and allow things to cool as you go, can assist with an air blower after each tack weld to cool it.
Less heat, less warpage, held firmly in place = less warpage.
Good Luck on your project, you will be an expert when finished.
