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I'm assuming that the area you're trying to fix is flat.
First you need a good die grinder or equivalent type of cutting tool. The bad are needs to be cut out but for beginners, make sure its not near a seam, weld, or curved area.
Go to Harbor Freight online and order a Sheet Metal Flange Tool, they've been on sale lately as well. This air powered tool creates a 'stepped' depression around the cutout edge and allows the replacement panel to sit flush with the body for welding.
Go to a metal supplier. A/C and heating repair shops are best. Tell them you need 16 guage metal for auto body repairing and have THEM cut the piece you need- they have all the toys to do that.
Try the new panel in the flanged recess where its going to be welded, then mig weld it in place. Now all you need is a small amount of body filler for the edges and prime coat a.s.a.p.
If you use a flange tool, remember to put sealer on the back of the panel after you finish the welding or you will most likely trap water. Because of that, I prefer butt welding even though it is more difficult to do. You can use a mig to weld the panels but a tig is preferred as the welds are much easier to manipulate with a hammer and dolly after welding.
No matter what method you use, only weld small alternating sections to minimize warping.
Yep. Thank you CJ. Forgot the sealer and warping issue.
@ the new guy: If you're nervous about all of this then you can cut and prep the area, get the new panel(s) shaped, then take your Jeep to a body shop just for the welding. A good shop does this almost daily and its amazing what a $20 bill can get.
Another tip, do some networking with friends and find a body man if you can. That same $20 and/or a case of beer can go a long way.
86 CJ7 Laredo Black
The Jeep was totally gone thru, 124k original miles on body,
New Crate engine and Trans, Weber Carb, Interior replaced back to stock, Dana 44 Rear, Dana 35 Front, 2.5 " Suspension Lift 1" body 33-12.50 Tires on Mickey Thompson Wheels, New Dupont Paint
forums , craigslist even, or sometimes the sunday paper will find you a good welder, either looking for some work etc, but i ve found some of the best welders through friends, the guy that took my skill from novice to nothing professional but enough to weld my own stuff nice and clean was my cousin's neighbor, he is an amazing welder so ask around
Am glad I read this, I have alot of learning and welding to do on a 73 CJ5 , Thanks. I will be looking for info on welding in floors, and side panels, as well as tail gate area, any idea of a good thread to read up? Thanks again for the info.