Rusty Quarter Panel Cut and Fold

Old 09-01-2016, 03:05 PM
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DenimDean's Avatar
Join Date: Jul 2013
Location: St. Joseph, MO
Posts: 1,453
Year: 1994
Model: Cherokee
Engine: 4.0
Default Rusty Quarter Panel Cut and Fold

This will be for those with quarter panels that are too rusted to do the regular cut and fold method.

It is a pretty straight forward process, you just need to do some cutting, hammering and welding.

This is what I had to work with.

1. Cut where the rust stops, for me it was around 1 1/4" below the fold in the panel.

2. Fill the gaping hole you just created. I was able to weld in the patch from the inside, your situation might be different... adapt to it.

(forgot to take a picture of it actually welded in... shame on me)

3. Time to start the cutting and folding. I used tin snips for the cutting, an angle grinder with a cut off would have been better, I just didn't feel like putting in ear plugs haha.

These pictures are in the order I went. I used the clamps to line the patch up to the fold in the panel.

4. Weld the folds in, seam sealer, and primer.

5. Clean up and straighten the fold. For this part, take your time and do small light hits with the hammer.

Rough fold.

Cleaned up.

And thats it!

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