Service Procedure

1. Remove the interior quarter panel trim and weatherstrip.

2. Cover the interior of the vehicle with a weld blanket.








3. Install the appropriate panel covers (quarter panel, wheelhouse, door opening panel) directly on top of the corroded sheet metal and scribe a line across the upper edge (Figures 1 and 2).





NOTE:
THE NEW COVERS ARE DESIGNED TO BE INSTALLED DIRECTLY ON TOP OF THE EXISTING PANELS. HOWEVER, IF THE CORROSION IS SEVERE, IT MAY BE APPROPRIATE TO REMOVE PART OF THE ORIGINAL PANEL (FIGURE 3). HOLE PUNCH COVER FLANGES AND GRIND OLD SPOT WELD AREAS AS NECESSARY FOR PROPER COVER FIT.

4. Remove all corroded sheet metal as required.

5. Sand blast floor pan inner member to remove rust.

6. Metal finish all edges. Spray surrounding surfaces, edges, floor pan inner member, outer wheelhouse cover, and door opening panel with Weld Through Primer.

7. Fit all three (3) pieces together for proper alignment on vehicle and provide plug weld holes (approximately fifteen (15) holes in door opening panel, fifteen (15) holes in quarter panel cover, and eight (8) holes in outer wheelhouse cover).





8. Clamp the door opening cover in places required to tightly secure all edges and MIG plug weld cover in place (Figure 4).

NOTE:
WHEN WELDING ANY COATED METALS, BE SURE WORK AREA IS PROPERLY VENTILATED.

9. Remove excess welding material.

10. Test fit outer wheelhouse cover and quarter panel cover to be sure the door will close properly.

11. Clamp the panel in places required to tightly secure all edges and MIG plug weld the cover in place.

12. Remove excess welding material.





13. Clamp the outer wheelhouse cover in places required to tightly secure all edges and MIG plug weld the cover in place (Figure 5).

14. Remove excess welding material. Spray Weld Through Primer on bare spots.

15. Clean area and remove the weld blanket.

16. Apply body filler to blend the cover to the body as required.

17. Cover inner wheelhouse opening as required and apply undercoating to the underside of repaired area as necessary.

18. Caulk the area with QWIK Seam Rubber Seam Sealer (flexible/paintable/waterproof/ weatherproof stock number CJ-B Black or CJ-N Neutral or equivalent may be used).

19. Paint the quarter panel with the appropriate primer and single stage or basecoat/clearcoat paint system.

20. Reinstall weatherstrip and interior trim panel.

NOTE:
REFER TO SLTS MANUAL FOR PAINT RELATED OPERATIONS AND ALLOWANCES.