PTEAZER™ EXTERIOR PANEL KIT
INSTALLATION INSTRUCTIONS
PART # PZPNX125 SERIES 040602

IMPORTANT: Be sure to test fit all parts to the vehicle before painting as PTEAZER™ will not be responsible for the painting on a defective part that must be returned.

NOTE: 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 filler.

4. Remove 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.

7. Remove the entire lower bumper-mounting flange of the quarter panel below taillight, as the flange on the fiberglass panel will replace it.

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.

11. Remove 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.

15. Grind 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.

19. Before 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.

20. Repeat steps 13-16 on other side. Then go back inside and use up any leftover adhesive on any missed spots.

21. After 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 number 877-783-2937.

IMPORTANT INFORMATION:
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. Toll-Free Tel: 877-783-2937

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.

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