During a restoration of the car, the front wings and a portion of the rear wings were removed to repair the sills. The dogleg section, the area behind the door, below the trim strip, and forward of the wheel was cut out to install the sills. The material removed for the sill replacement will determine the method used to install the wing repair panel in that dogleg area. The best option was to leave a least 3/4 inch of metal below and behind the door opening.

Tools and equipment used to complete the work were a air body saw, air chisel, angle grinder with 36 and 50 grit disks, rotary tool with carbide cutting tip (Dremel), air hole punch/flanger, big hammer, tape measure, vise grips, c clamps, clecko, MiG welder, auto darkening helmet, safety glasses, gloves, ear protection, and dusk mask.

Before cutting any metal, take a pen, paper, and measuring tape, and record measurements. Take measurements of the door opening, the distance of the edge of the wheel well to the trim line edge, the depth of the wheel well, and other points that will be beneficial for reference when fitting and welding.

There are two fitting methods butt or flange that can be used when installing the repair panel.  The butt method the repair panel is cut to fit where the edges of the panels will butt against each other without overlap.  This method requires precise cutting and fitting.  The butt method done correctly will blend new pieces with the old and finished will look like an original panel.  The flange method is where a panel edge is formed to fit under or over another panel providing a flat flush fit. The flange can be pressed into the repair panel or the area surrounding the repair panel.  The flanging method is more forgiving with measurements because the overlapping flange.  When repairing the rear quarter lower half one or both the panel fit methods can be used.

The repair was started by deciding how much of the lower half of the wing was to be replaced. In many cases, the area behind the wheel to the tail lamp is not rusted and does not need replaced. A bit of work can be saved by not replacing the complete lower half. As they say across the pond, offer the repair panel up to the wing to observe the panel's fit. Use a marker and draw the rough cut lines on the car's wing. Drawn a line across the wing using the bottom of the trim as a guide or if the trim piece is removed estimate the bottom edge. Mark a line 3/4 inch behind and below the door following the contour of the door opening. This area can be flanged for the fitting of the repair panel. If the rear of wing is in good condition, mark the wing where the repair panel will end.

Removing the old lower wing. When replacing the entire lower half wing locate the wing valance seam and drill out the spot welds, below the trim line grind the edges tail lamp, clean up with hammer and chisel, and cut the seam below the tail lamp. Drill the spot welds in the wheel well and wing edge. Using a air body saw or angle grinder with a cutoff wheel, cut the wing along the marker lines.

Preparing the repair panel. You just cut a big hole in the side of your car, now you are committed to finishing the job. This is when fitting and measuring will be repeated until the repair panel is trimmed and flanged to match the body. On the 67B, the front end of the panel where it meets the sill is folded flat. The repair panel will have this edge folded at 90 degree angle. The end will need to be folded over or trimmed for the leading edge of the panel to lay flat with the sill. Offer the panel to the car and clamp the wheel well edge to the outer wheel arch and along the sill bottom. The front lower portion that covers the sill should have a gap between the sill and the end of the dogleg. Check the fit at the tail lamp if replacing entire lower half. Adjust the repair panel for best all around fit. The repair panel will need to be trimmed to fit at the top and door. Mark the repair panel for cutting leaving 1/2 - 3/4 extra metal on the edges for fitting and if using flanges. Remember how much you paid for this piece. Measure 3 or 4 times and if needed cutting twice is much better that cutting it to short. Cut the repair panel with a air body saw or angle grinder with cutoff disk. Offer the panel for fitting again. Be careful not to fold or bend because the supporting panel edges have been removed. Trim again if required. Using a hand tool or an air punch/flanger, a flange is made in the repair panel. The flange will fit under the wing along the top and at the door!!!!! Again, offer the panel for fit. The flange will allow the repair panel and wing to set even to the other. Set the panel for welding with cleckos, screws, vise grips, C clamps, and/or magnets.

The repair panel is ready to be welded.  Using a MIG welder with gas shielding, proper setting for heat, and wire speed, tack the repair panel in place.  Continue welding the panel with short welds of about 1/2 inch length.  A longer weld will risk overheating the metal and warp the new panel.  Space the welds about the repair and continue welding with taking an occasional break to allow the panel to cool until the all the welds are joined. Grind the welds level to the panel with an angle grinder fitted with a 50 grit disk.

If the job went well there will be very little glaze filler used to smooth the panel imperfections.  Locate and drill the holes for the trim piece. Prepare for primer and paint.