Tail Panel removal - need procedure

GERMYS_72 · Oct 12, 2024

For those following my tail panel saga, I did a test run of cutting out the middle section using the Taiwanese panel. The previous owner did a nice job cutting out the middle rusted section of tail panel. I'm confident I can graft in the missing section using the NOS panel and make it look good with weld,metal filler/primer. There is nothing wrong with the light bezel sections on the car now. I know the purists out there are going to think this is a troll, but I don't want to gamble and take this to a body shop only to find out they tear the tail panel out and do a worse job that I would have.

What's the difference between adding metal filler on the outer edges of the panel at the quarters, or in this middle section where it will be covered by honeycomb and bumper anyway ?

Let me know what you think.

Stanglover · Oct 12, 2024

This is just my unqualified opinion as I'm not a bodywork "expert", but if it were me, I'd replace the entire panel. My thinking is this; If the picture of the inside (pic #2) has that much rust already in the steel, before too long it's going to eat through and cause pin holes, or worse, around the taillights. Even if you use rust killer, I wouldn't trust it.
Going back to when I did mine, the only rust on the entire car was pin holes around the taillights. There had at some time, been some light damage to the panel, but that was entirely fixable, the rust wasn't, so out it came.
However, it's your car, your decision.

GERMYS_72 · Oct 12, 2024

Stanglover said:
This is just my unqualified opinion as I'm not a bodywork "expert", but if it were me, I'd replace the entire panel. My thinking is this; If the picture of the inside (pic #2) has that much rust already in the steel, before too long it's going to eat through and cause pin holes, or worse, around the taillights. Even if you use rust killer, I wouldn't trust it.
Going back to when I did mine, the only rust on the entire car was pin holes around the taillights. There had at some time, been some light damage to the panel, but that was entirely fixable, the rust wasn't, so out it came.
However, it's your car, your decision.

The #2 pic is the NOS tail panel sitting under the original piece previous owner cut out. It's way more rusty than the ebay pictures let on.

Stanglover · Oct 12, 2024

GERMYS_72 said:
The #2 pic is the NOS tail panel sitting under the original piece previous owner cut out. It's way more rusty than the ebay pictures let on.

Oh that sucks!! NOS means "New Old Stock" not "old rusty piece"!

GERMYS_72 · Oct 12, 2024

Stanglover said:
Oh that sucks!! NOS means "New Old Stock" not "old rusty piece"!

it's RNOS

Bentworker · Oct 12, 2024

I’d take a hard look at your tail panel where the light gaskets make contact. Honestly the tail panel is an “easy” job as the weld points are hidden by the tail extensions and rear bumper. Personally I’d replace the entire panel. I’ve done it on my 71. Get good lighting, clean everything so you can see and get to work. If needed use some liquid courage such as vodka.

Don’t do it if you are a gorilla and will let frustration and brute force take over.

Hemikiller · Oct 12, 2024

Do the entire panel. You can strip all the rust off the NOS panel chemically.

fd7 · Oct 13, 2024

I replaced the whole panel, glad I did. Sometimes, just doing a whole panel is easier than trying to piece something in.

GERMYS_72 · Oct 13, 2024

fd7 said:
I replaced the whole panel, glad I did. Sometimes, just doing a whole panel is easier than trying to piece something in.

looks great

GERMYS_72 · Oct 13, 2024

I'll see if I can rig up an Acid bath for ole Rusty NOS, and will revisit slapping in the entire panel.

GERMYS_72 · Nov 18, 2024

Today was the day. I ended up using a plasma torch to melt through the spot welds. 1 inch putty knife to break through the residual weld, and also the 3/8 inch belt sander to sand down the welds from the tail panel side inside the trunk. I just worked my way around carefully until it was free. I personally did not find it very easy to drill the spot welds out with the special bits, but others might have better luck doing that method. This was my first tail panel removal.

I also dipped each side of the NOS tail panel in Vinegar solution to remove the rust. Too many people on this thread to thank individually, but I appreciate all the advice. In the end, it was definitely better to install the entire tail panel, it's already looking great.

Tail Panel removal - need procedure

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