PART # PZPNX125 SERIES 040602
Be sure to test fit all parts to the vehicle before painting as
will not be responsible for the painting on a defective part that
must be returned.
The panel conversion requires intensive bodywork.
The installation of the panel conversion needs to done by a professional
body shop familiar
with the fabrication of fiberglass to steel bonding requirements.
1. Remove all trim from the rear doors and quarter panels including
hinges, latches, window glass and motor mechanism
2. Now remove
outer skins from both rear doors using a grinder or cut off wheel.
Cut an extra half-inch from front edge of door. This will help
when setting fiberglass panel in place.
Note: Remember to cut skin from above window openings also.
3. Weld up
hinge bolt holes in center pillar and finish smooth with body
outer skin from quarter panels by coming quarter inch inside door
opening and cutting parallel to outer edge. This means taking
the entire wheel opening off. Continue along the top of the rocker
panel until you reach the front door edge.
5. At the
front door edge measure back a quarter inch on the rocker panel.
Now make a VERTICAL cut of about two inches down the rocker panel.
At the wheel opening cut about one inch off the end of the rocker
panel - the remaining rocker panel will now be bent in allowing
the fiberglass panel to mount flush at door edge.
6. At the
rear of quarter panel, either drill out spot welds or cut off
outer skin with a cut off wheel or air chisel.
the entire lower bumper-mounting flange of the quarter panel below
taillight, as the flange on the fiberglass panel will replace
8. The same
thing around the gas door opening - cut it off, as our fiberglass
panel is more than strong enough to mount either the factory fuel
door or our PTeazer Billet fuel door.
9. Once the
skins are all removed, you will need to fold the rear lift gate
door jam over towards the outside of the vehicle. This will help
the fiberglass panel slide over the lip.
10. At the
top-most rear corners of the vehicle, there will be a reinforcement
panel of double thickness boxed metal. This is located behind
and above the rear quarter windows. You may need to cut a line
along the top edge and hammer this metal in about quarter to half
inch. This will help to align your fiberglass panel with rear
door and roof.
door weather strip. Grind several areas of the painted surface
around the doorjambs to enable a secure tack weld for holding
the doorframes in place.
12. Push doorframe
back into doorjamb as tightly as possible and tack weld into place.
13. Hold up
panel to test fit before attempting to permanently mount. Adjust
the gaps at front and rear doors by grinding the backside of panel
if necessary. If you find the rear lines up, but the front gap
is too wide, you can cut more off or hammer in the remaining inner
wheel well. This will allow the side panel to move in closer and
it will close the gap at the door.
14. When you
are satisfied with the gaps, mark the front door pillar and remove
panel. Weld three flat sheet metal tabs on the pillar to screw
panel to. REMEMBER to allow for thickness of fiberglass.
paint from all surfaces where panel will attach to body.
16. We recommend
the following two products that work very well to attach panels:
1) Kent Industries 45 Epoxy Adhesive, 2 packages, and
2) Corvette Adhesive from Fiberglass Evercoat, 1 gallon.
Preferably, it takes three people to install each panel due to
the critical time limit once the corvette repair material has
been activated. Follow the adhesive directions carefully.
17. Only when
you have achieved the final fit desired, put the Kent 45 on all
the inner structure that will come into contact with the fiberglass
panel. Next, using three batches of corvette repair adhesive,
have one person spread a one-inch thick line of filler along the
edge while the other two do the rear and the pillar. Try to accomplish
this in about five minutes, and then mount the panel permanently.
18. Use screws
to hold panel in place as necessary so it does not move out of
alignment as the adhesive is setting.
adhesive dries, use a rubber glove and your finger to clean excess
adhesive from doorjambs. This will save you lots of finish sanding
later. Feather roof line out with a spreader and wait for adhesive
to dry - about 30 minutes.
steps 13-16 on other side. Then go back inside and use up any
leftover adhesive on any missed spots.
panel is installed, flush in along rocker and roof line. You can
leave screws in on underside of rocker panel, but you should be
able to remove other screws and repair small holes.
22. THOROUGHLY SAND AND PREPARE FOR PRIMER AND PAINT using a high
quality automotive primer and paint. Fiberglass parts require
detail work and will need to be sanded down thoroughly.
For technical assistance, please call our toll-free telephone
Your installation of this part constitutes an agreement by you
agree to hold harmless PTEAZER, INC. for any responsibility whatsoever
for damages or injuries as a result of installation, use and misuse
of these parts. PTEAZER parts and accessories are protected
by trademark, copyright and patent. Any attempt to reproduce,
or otherwise copy any part or accessory will be aggressively prosecuted
to the fullest extent of the law. PTEAZER INC. warranties all
parts 100% prior to painting or installation.
Please report any shipping or other damage immediately upon opening
of package. All damages must be reported within 5 days of receipt