Back to basics: Exterior panel fit up 

Sometimes, going back to the basics can make the difference between a quality repair and a failed repair. Proper fit-up of exterior panels is vital for a successful repair when replacing them. 

Proper exterior panel fitment affects how the customer perceives the repair’s success. Test-fitting panels helps to ensure proper alignment with adjacent panels and parts, preventing damage during assembly. Fit the panels with the vehicle level and suspension loaded or on a fixture bench. 

When installing welded-on panels: 

• Test fit the panel by installing and securing it with temporary fasteners, such as locking pliers, clamps, or spring clips.  

• Check the panel alignment with adjacent panels and parts before welding. 

• Mark the panel’s location using markers, tape, etc., to help realign it after test fitting. 

• Always use OEM recommended welding equipment and processes.  

• Use welding techniques that limit the heat/panel warpage. This reduces the chance of welding affecting the panel fitment during assembly. 

Some vehicle makers provide panel gap and fitment information in the vehicle-specific repair manuals. If not, you can usually compare the panel gaps and flushness to the other side of the vehicle.