GM Trunk Repair - Do It Yourself Trunk Repair

The replacement panel eliminated a rib. We used a piece of wood to hammer it into shape and close up the gap before we welded.

With the replacement panel firmly in place, we stitch-welded the panels with the Craftsman MIG welder on a low power setting, working slowly around opposite ends of the panel to prevent warping the new panel. Then we removed the screws, welded each hole, and ground the welds smooth for a finished look.

After grinding, we smoothed the overlapping panels with a thin coat of Bondo and let it cure. We also sealed the area between the new panel, the wheelwell, and the bottom side of the overlapped panels with 3M Heavy Drip Check to prevent moisture from lodging between the overlapping panels.

With the sanding completed, we finished the job with a coat of primer and paint and used a couple cans of trunk-spatter paint to give it that '60s OE look. Then we replaced the old gas tank with a new OPG replacement tank.