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Wanting tips for cutting from a donor car

Hi, just wondering if anyone has any tips for measuring and cutting sections out of a donor car. I have a HR wagon with rust at back of rear windows in the corner and down beside the tailgate, just not sure on how to cut and measure and piece. Any help appreciated.

Thanks

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cut way way more than you need and trim back to suit, lot easier to trim a bit off a few times than try to add some on
also invest the time to learn how to drill out spot welds and where possible do your repairs to existing factory joins you will find that existing joins and spot welded areas will be stronger so less warpage when re welding

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As Lesbo said above, cut way more than you need. Use the thinnest cutting wheels, so much quicker (but yes, they wear out quicker). A 9" grinder is very handy too, they cut a lot deeper, sometimes you can get the inside and outside panels at the same time.
And the most important bit, take plenty of pics to share with us..

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Cheers, its the initial cutting that worries me, will give it a crack, not sure if i can get the attached in one piece, but will definately cut bigger and drill out the spot welds, assuming i cut the donor first?

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I'd cut that whole section out of the donor car, the bigger the better. Then separate the outer panel from the inner (if you've got the inner as well as the outer), so you have a nice outer-donor panel. You might need to do the drilling out spot-weld bits here to separate the inner and outer. Place the donor panel over the real panel on the car, trace it out, then cut away (cut inside the line of course). Make sure you've gone back far enough to find nice metal.
I hope that makes sense. Good luck..

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........๐“ฃ๐“ฒ๐“ถ.

โœ„--------------------------------------------------------

-_--_--_ _______._
_--_-_ -/___+__|__\__
.,.,.,,.,|_O ________O_|

yup as Tim said cut the whole section plus at least 50% bigger from the donor car,then strip it back to bare metal, once you have done that it will become more apparent where the spot welds and different sections are,then use this as a guide to determine where to remove sections from the car being repaired, some of the simpler ones like the bottom edge of that window frame may be able to be patched using plain flat sheet. Ive chopped flat sections from things like old rusty doors before today to get a donor piece of steel. measure twice cut once...

Edit .... On areas like the body line below the rear corner, you can buy a tool pretty cheap that will swage an offset on the edge of a donor panel allowing it to overlap under the original metal. depending on your welding ablity this might make it easier for you to do halfway down to that body line rather than trying to do a butt weld https://www.ebay.com...

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Thanks again, have ordered the offset tool, and will make sure i cut more out then need. Will take photos as i go.
Much appreciated.

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Donโ€™t forget to spray โ€œrust proffโ€ in the areas ๐Ÿค”

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"just my 2cents worth"

"were going to need a bigger shed"
trippled75@yahoo.com.au
This will take You to" Old Holden sheds"
https://web.archive....

all good advice above
i screw or clamp the panel on before making a final cut easier to make adjustments before welding it
i get the cut section sand blastered to make it easier to see the spot welds
if you leave at least a inch over lap once you have removed the rusted section you can place the replacement over the area and use a marker to put lines where you need to cut so that you get a straight cut matching to butt join it
make sure you fit the tailgate to align the gap beside it

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Thank you

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