Do It Yourself Hot Rod Kustom Website

	Replacement Panels - 1954 Pontiac Rocker Panel The rocker panels, bottom of the rear quarter panels and the bottom of the trunk lip were rusty and needed replacing. I had purchased replacement panels from several sources a couple of years earlier (as I found the funds, I put the money to good work before I spent it on other things like food and necessities of life!). While I was at it, I figured it was a good time to replace the square gas cap lid with a round one off of a 1980s Chevy. Here's the driver's side rocker panel - bent and rusted The replacement panel and old rocker primed cause I was tired of looking at a rusty green car I spent a lot of time marking where I wanted to cut. I left about 1/8" more than necessary so that I could fine fit the piece. I found that an every day jigsaw cuts sheet metal very well, straighter and faster than typical bodywork tools like a die grinder or air chisel. Expect to break a lot of blades though - you can keep reusing the shorter and shorter blades though. Used a jigsaw, die grinder and 4 1/2" grinder to cut out the old piece I don't have a picture that shows the complete side which shows how much was cut off. I measured and marked and cut off the rocker panel, 8" off of the bottom of the quarter panel, 4" off of the complete wheel well lip and 8" off of the rear of the quarter panel. Finished rocker panel Driver's side door jambs finished The rocker panel was MIG brazed in place which worked very well. I used MIG brazing because the temperature is cooler than MIG welding by about 500 degC which means less chance of warpage and burn through. It worked very well for the rocker panel as there are lots of bends in the metal to prevent warpage and the metal was very thick and solid where I brazed. Filler was used to smooth out joint. Quarter Panel I don't have a picture of the quarter panel cut out unfortunately or maybe fortunately, because its quite scary when half the panel is missing. I had a very difficult time mating up the three patch panels together. Here's what I started with: Lower front of the wheel well Rear of wheel well Driver's side quarter panel finished and waiting for epoxy primer Quarter panel showing new round gas lid/door opening and high spot that was shrunk flat using the incredible shrinking disk Driver's quarter panel primed with high solids and ready for block sanding Trunk lip Bottom of the driver's side taillight Driver's side trunk lip cut out, replaced and a layer of filler just cheese grated and ready for sanding Passenger side trunk lip cut out and waiting to have new lip welded in Trunk lip primed and ready for block sanding Passenger side rocker panel cut out and interior rocker panel plate welded in Passenger side rocker panel replaced and body filler added front view Passenger side 1/4 panel with replacement panels ready for primer Here's the car painted and bodywork completed.