1966 Ford Mustang - Project '66 - How To: '65-'66 Taillight Panel Replacement

7 Next, cut away the major section of the taillight panel with a cut-off wheel or reciprocating saw. If you've already replaced your quarters or if they are in good condition, make sure you do not accidentally cut into them.

8 Once the taillight panel has been set free from the back of the car by your saw, carefully pull the old metal away. We stress carefully because again, you may have missed a spot weld somewhere.

9 The remaining small sections found in each corner can be removed by using a pair of locking pliers to break the strips of old metal free. Simply work the section of metal back and forth until it gives up its hold on the end of the quarter-panel.

10 Before fitting the new taillight panel, take a few minutes to remove all the old seam sealer found in the corners, using a rotary tool and a cutting bit. Having clean, rust-free metal to weld to will make for a stronger, longer lasting repair.

11 Our '66 hardtop has its taillight panel completely removed now. This is the halfway point of the project. Next are panel prep, measuring, and installation of the new taillight panel.

12 Depending upon how you install your new taillight panel and what your vendor sends you, there is a strong possibility that this small modification will need to be completed. The last inch on each end of the taillight panel's top edge will need to be bent flat for installation, as shown here.

13 Looking at the old taillight panel will help you determine where the new taillight panel will need to be welded. At these junctures use a drill or punch to make small holes to allow MIG-welding of the panel.

14 Using the alignment tabs along the bottom of the taillight panel, as well as the taillight housing mounting stud holes, the taillight panel is clamped into place using locking C-clamp pliers. Having the trunk lid on the car helps at this time for alignment purposes.

15 With the taillight panel in position, lay down a few tack-welds along the bottom edge (to the rear crossmember) to hold the panel in place initially.