Hi Steve
All the above. I'm not an expert, but I started helping my Dad nearly sixty years ago and I do body work as lot of people play music. By ear. Generally, you start by looking for spot welds and drill them out and seperate panels wherever you can. Then, check your new panel or piece and mark-off where you want to cut. There is a tool that I find valuable - ordered mine from northern tools (it's air, though but will work with a sears 5hp compressor) that will punch holes to spot-weld through and the other side puts a flange on metal that you can join two pieces to fit flat for a weld. Pop-rivit guns help a lot by holding the metal together while you start the weld and can be drilled back out and the holes welded up. Whenever I can, I will use a jig-saw. Makes the cut go faster. Since I worked in sheet metal about fourty years ago, I learned how to use tin snips and they can be of use in shaping the piece to be replaced. You need a right, left and straight cut (all three pairs). A small wire welder is really a must to stitch panels together and a grinder to grind the welds so it looks as if it was part of the same panel, and of course body filler to smooth over the course places. But, I'm sure that you will get a lot of good advise from people and eventually you will develop a system of your own with a mixture from everyone. Keep up the patience and don't give up. Takes time.
Truck Tinker
