Quarter Panel fix options

Hi all,

I just bought a 97 lumina. most things seem to be in top shape but the driver side quarter panel is rusted out in an area of about 5" by 5" just below the fuel cap.

Since the quarter panel is a seperate piece my first option would be to just replace it. Has anyone done this? I don't see the procedure in the Hayne repair manual. Is it a very involved job?

If this is not viable without bringing it to a body shop.. is it viable to fix with a body kit? I noticed there are multiple layers of sheet metal seperated by foam. Could an amateur properly fill this gap?

Thanks

Ha! I have a '97 beginning to rust through in the same spot...must be a salt/dirt trap related to the filler pocket....my friend who does body and paint for a GM dealer tried to explain the problem to me on the phone, but we are gonna have to take it apart and solve the root problem, or it will just eventually blow out around a repair...


Replacing a rear quarter is something that experienced body repair guys don't even care much to do if they can avoid it...not a job for the DIYer...

Replacing a rear quarter is something that experienced body repair guys don't even care much to do if they can avoid it...not a job for the DIYer...
Could be salt trap forsure. I am also in the frozen north.

That's incredible eh, from the outside there doesn't seem to be much to it. I asked because I read in a comment somewhere that it was a 16hr job by a pro and I was hoping it wasn't true for the lumina.

Are you leaning towards replacing the panel or patching it after you find the problem?

Once you figure out what you're going to do please relay your experience if you remember to :p

Thanks for the insight.

I can tell you with almost 100% certainty that the rust started from the inside, and there will be nothing left of the panel under the gas door once you strip the rust.....

It's a bad design from GM. The foam pads between the inner and outer quarters by the gas door on luminas/MC's have probably been wet since the day they rolled off the assembly line, and it never dries. The only real solution would be to replace the quarter panel, or at least a cut-out of and around the gas door from a donor car. But yes, this is quite involved, and like Jeffcoslacker said, most body shops don't like to do this if they don't have to. You could do what I did, and get rid of all the rust, and create a fiber glass patch panel for it, and re-spray the quarter, but believe me, this is not an appropriate fix. I did mine a year and a half ago, and what was left of the steel part around the gas door is bubbling already. Best solution? Depending on what you think your car is worth, live with it.....unfortunately. If you really think it's worth it to fix, you need to replace the sheet metal to do it right, and it'll cost you.

Thanks both of you. Sry for the late reply.. I was having coolant leakage issues and was stressed about the intake gasket.. Turns out it was just a hose :p:p:p... So the rusty quarter panel is back to the top of my list of things to do with the car. I see now why the quarter panel is so difficult to replace. Too bad it's such a complicated piece.. and from what I can see for basically no reason...

It's mostly just an eyesore as there is absolutely no rust on the rest of the sheet metal so I will be doing something. When the weather warms up a bit I'll probably do what dwalmop ended up doing.

Thanks again,

Replacing an entire quarterpanel requires cutting at the roof line, breaking welds at the rear door opening, breaking welds at the deck and rear body panel, and along the lower pinch to the trunk floor. It is generally easier and a completely acceptable practice to cut away damaged metal from the panel and weld in repair panels along a character line or seam.

The area in question is the intersection of the outer panel skin and the inner wheelhouse flap. You can see a gap in the photo where the infamous foam filler is supposed to close the opening:

http://72.19.213.157/files/W-QuarterRepair.jpg

The detail of rear panel connection and deck lid opening are seen here:

http://72.19.213.157/files/W-DeckRepair.jpg