Lower quarter panel chop DIY

eurosonic

Expedition Leader
Really enjoyed boo471 Lexus bumper build, so I figure Id share another common mod that can be done on many expo rigs on this site.

Im reposting this from my build thread. This is something Ive done few months back in preparation for a rear bumper build. I also later did a rear frame tuck along with a gas tank lift, you can check out my thread for pics and info on that.






Finally had a chance to get some work done on the Mitsubitchi. I banged the rear lower quarters few times on the trails so it was time for them to go.

This was a new experience for me because it was my first time welding. Always wanted to learn, figure this would be a nice simple project to get started with. After picking up a Lincoln 180 I practiced on some on scrap before jumping into this. My next-door neighbor is a certified welder with 30 years experience, so he showed me the ropes on what and how. Of course few hours on YouTube helped as well!
Over all this was a fun project, I recommend anyone on here to give this a try.

Plan was to chop the lowers up to the first ridge, which lines up well with the rear body line.


Ready to go :)




Beforehand I bought some 20-gauge plate from a local metal supply store for $3.



It was much easier to do this with the wheel off.



Masked the cut line



First used an angle grinder to cut, no going back now.





Finished it off with a sawzall



To trace the shape for the filler plate I used a piece of cardboard which I pressed against the chopped quarter.



Fits good



Traced it on to the plate



Some prep for welding



Tacked it onto place



Finished the rest and cleaned up the welds






Same on the other side




Used this stuff over the nastier welds behind the panel




For now I sprayed it over with primer, later will do the sides with bed liner.







Moved over the drain and plug








 

eurosonic

Expedition Leader
While the wheel was off I rolled the inner fender lip. I had it rub against my tires few times and once took out a small chunk. If you have 35s this needs to be done.











Here are the results. Once the rear bumper gets built, it will wrap around to protect the body.





Next on the list - rear frame/gas tank tuck.
 

eurosonic

Expedition Leader
heres a pic since the rear frame and gastank lift was done. Will starting building the rear bumper over the holidays.

 

iluv83vettes

Adventurer
People do that with XJ Cherokees a lot, but instead of just cutting it off, they leave the out "skin" like a flap and fold it over so you don't need to use new metal.

Looks nice!!!!
 

pappawheely

Autonomous4X4
Nice work. Glad to see you did not forget the drain. I have seen people forget to do that only to have the area rust out in short order.
 

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