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Before I attempt to replace the quarterpanel on my 68 Cougar, I thought it would be a good idea to ask if anyone has any helpful tips on the best way to do this. I have a NOS quarterpanel and don't want to take any chance of ruining it. I have replaced other panels, such as the floor and firewall, but never a quarterpanel. Any advice would be greatly appreciated.
 

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Is it a FULL factory QP,...with sail panel and trunk drip-rails? If so, replace at factory attachment spot welds. This will require removing the lead seam at the sail panel to roof panel,...propane torch and a 3/4" wood chisel will remove the lead fast. Remove the lead a layer at a time and don't overheat the surrounding sheet metal..... work outdoors!
If it's a repair panel,...butt weld at 1/2" below the main top body line. This is a strong attachment point and will be less likely to cause sheet metal warpage. Attach using small spot welds,...... rotate the spot welds, spacing them 5-6" apart, until a solid weld seam is formed.
 

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It is a full factory quarterpanel and I appreciate your advice. I would also like to know if there are any special way that I should be supporting the car before taking the qp off. Thanks.
 

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Also good advice from 67 . I would take my time welding in the quarter specially along the seam . If it takes 5 days you will not heat it to the warpage point and besides why get in a hurry . Also add fit and refit the panel . I placed the quarter on with self tapping screws and assembled the quarter extensions to the bumper .

This time spent fitting will make sure the width or narrow parts line up with the bumper you are using . If you look at my 67 album link below you may get some ideas from what i did .
 

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The QP maintains 20% of the structural integrity of the rear of the car. Support the car at the torque boxes and the frame rails. Level the car and brace trunk area as needed to maintain alignment. Diagram and measure critical reference points inside the trunk. Align trunk lid and door. Here's a few videos showing important points in removal and installation;
http://www.youtube.com/watch?v=O40nbcAW8Ew&feature=relmfu
http://www.youtube.com/watch?v=T5FvyklESvI
http://www.youtube.com/watch?v=hf7zhin8UoU
http://www.youtube.com/watch?v=V07S0hnFa4Q
 

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Whatever you do, before you weld on the car, make sure you disconnect the battery. Welders are DC charge and you may have a voltage issue and burn out some electrical components on your 12v system, don't ask me how i know this,,,,
 
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