68 Camaro 1/4 panel repair

[Lizer]

At one point I did it that way, however I now position the patch panel and then trace the outline where it will be welded. Then I remove the patch and cut inside of that line. This gives a much better fit and eliminates the gap for the most part.

If you cut with a cut off wheel and make your cut at a 45 degree angle ( or thereabouts), it will make that gap a lot smaller. My problem with tracing is if you deviate from your line at all you’ll have a big gap or tight spot there.

 

['68 Coronet R/T]

If you cut with a cut off wheel and make your cut at a 45 degree angle ( or thereabouts), it will make that gap a lot smaller. My problem with tracing is if you deviate from your line at all you’ll have a big gap or tight spot there.

In my experience the tracing reduces the number of large gaps, especially if you are careful with the cut off tool.
When I did my first ever quarter panel on my signature car, I had gaps like this:

Took some time to get it to here:

 

[Lizer]

If you cut with your cutoff wheel perpendicular to the panel you’ll get a gap like that and indeed is little more challenging to weld. With the cutoff wheel
blade going through the metal at an angle it reduces that gap by about half. Makes it very tight.

 

[OJ86]

Air saws are the best for cutting on traced lines IMO. Specifically for TIG welding, with MIG you have much more room for error on the gap.

Lizer is correct on when cutting with a cut off wheel, angle your cut and you will get a much tighter gap.

 

[chevman]

I like to do it as '68 mentioned. I think its just a matter of getting the patch panel sitting on there good, and some of the edges have to be trimmed off in order to get the patch to sit in just the right place.

I was able to fusion weld a lot of it with a tig and no filler rod. Its a 57 Chevy hardtop

 

[Chevynutz]

I basically did like 68 suggested and the the gap was tight and had to open it in a few spots for correct fit. I have done the cut and butt angling the blade as well which worked pretty good on a small patch panel. I'm happy how it turned out but could have planished it a bit more. One thing i also do is close the garage and make it dark and check for pin holes from the back with light. A major milestone as 99% of metal work is done. Maybe get this thing in color someday !

 

[chevman]

had to open it in a few spots for correct fit.

That is expected. I use either a body saw, or a cut off wheel to get it close, then tin snips to cut right up to the line. Trying to cut off too much can cause distortion while cutting with the tin snips.