Install Rear Quarter Panels



		Bronco Rear panels install tips

Use masking tape and create a layout area you can see easily. We are going to put 4 large captive dzus mounts next to the door , 2 below the window and 4 at the rear tailight area. You may want to vary the locations to suit your needs.



			Using a small hole saw or panel drill locate centers and drill all inside holes as shown to the left. This will create a nice radius for neat appearance and less cracking problems later. The round edge of the od on each tab can be cut easily with sheetmetal snips. Note the 2 small and 1 larger hole on each tab. this is the layout for the dzus spring mounting and the hole for the dzus to go through.


	We are coming straight across from the window to the door edge here to make a large area for the top dzus mount. ( It will be in the black above the tape line) . You should put a dzus near the center of this area for the top dzus mount. This will keep the top section pulled down tight to the sheetmetal.




					This is what your sides should look like after the layout is done and your hole saw work is complete. It is a good idea to get all the holes done before cutting the panel loose. It makes the hole work go easier as the panel is strongest before cutting. If you try to drill the tab afterwards you will create some problems for yourself. This is where a lot of time is spent so the job later will go smoother. Note over the tailight the corner is left one piece like the top door edge dzus mount . This is to make it strong enough to hold the panel in place. On these two areas the panel should lay flat by design. The rest of the tabs will have to be bent slightly to match the angle of the sides. Remove the gas door and inside fill assembly from the outer skin.




	Using a die grinder with a thin cutting wheel cut between the holes of your layout. Take your time as the panel can grab the wheel and shatter if you rush it. Connect the dots so to speak. You will need to cut the inner support piece that joins the inner wheel well to the outer wheel opening edge. Do this by cutting the spot welds that hold it to the inner wheel well and the rest comes off with the side panel when you are done.



					Right side after cuts are complete. After tape is removed sand all edges for neatness. Assemble the springs to the backside of each mount and rivet into place. You may need to sand the fiberglass where each dzus is to remove any imperfections that might keep the panel from fitting properly.


	I would recommend when you have the panel correctly located mark 2 holes at the top first . Drill the panel and prepare the hole for the fit of the large captive dzus. Clip the panel back on with the 2 dzus mounts and check the fit . Using duct tape get the rest of the panel in place then mark all the holes at this time. This way if you are off the mark you only have to adjust 2 holes. The gas fill neck will have to be lengthened about 2" or so. This way you can maintain the stock fill hose.

					On the left side of newer model broncos the gas door is slightly different. If you have a problem trying to make it fit I would locate one from an earlier bronco and use it. On the 95 bronco that we installed sides on I used polyester filler and changed the opening to work with the new style door. It takes a little work but can be accomplished . Also you will have to fit the back portion somewhat as it is a little different from the earlier year model broncos.