Installation Procedure

The quarter panel may be serviced as a complete panel in the event the roof panel is to be replaced. Sectioning procedures have been developed to simplify the repair. The service part can be replaced by making sectioning cuts at the window pillars.

Fig 1: Replacement Quarter Panel Cut
Courtesy of GENERAL MOTORS CORP.
1. Cut the replacement quarter panel in corresponding locations to fit the remaining original panel. The sectioning joint should be trimmed to allow 1.5 times the metal thickness at the sectioning joint.
Fig 2: Creating & Trimming Backing Plate
Courtesy of GENERAL MOTORS CORP.
2. Create a 50 mm (2 in) (a) backing plate from the unused portion of the service part. Trim the backing plate as necessary to fit behind the sectioning joint.
Fig 3: Drilling Plug Weld Holes Along Sectioning Cut (Quarter Panel Sectioning)
Courtesy of GENERAL MOTORS CORP.
3. Drill 8 mm (0.3 in) plug weld holes along the sectioning cut on the remaining original part. Locate these holes 13 mm (0.5 in) from the edge and spaced 40 mm (1.6 in) apart.
Fig 4: Drilling Plug Weld Holes In Service Part (Quarter Panel Sectioning)
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: In any area with excessive damage, space the plug weld holes every 40 mm (11/2 in) apart.
4. Drill 8 mm (0.3 in) plug weld holes in the service part as necessary in the locations noted from the original panel and along the sectioning cut.
Fig 5: Applying Weld Through Primer To Bare Metal Surfaces (Quarter Panel Sectioning)
Courtesy of GENERAL MOTORS CORP.
5. Prepare all of the mating surfaces as necessary.
6. Apply 3M Weld-Thru Coating P/N 05916 or equivalent to all mating surfaces.
7. Fit the backing plate halfway into the sectioning joint, clamp and plug weld to the vehicle.
Fig 6: Aligning Quarter Panel To Vehicle
Courtesy of GENERAL MOTORS CORP.
8. Position the quarter panel to the vehicle.
Fig 7: Plug Welding Quarter Panel
Courtesy of GENERAL MOTORS CORP.
9. Plug weld accordingly.
CAUTION: Properly seal the fuel filler opening before you position the quarter panel. Failure to seal the opening could allow exhaust gas to leak into the interior of the vehicle, causing personal injury.
10. To create a solid weld with minimum heat distortion, make 25 mm (1 in) stitch welds along the seam with 25 mm (1 in) gaps between them. Then go back and complete the stitch weld.
11. Clean and prepare all of the welded surfaces.
12. Apply the following products, as necessary:
    • The sound deadening materials
    • An approved anti-corrosion primer
    • The sealers and refinish as necessary
13. Install all of the related panels and components.