where to cut for panel replacement?
 

hello, just wondering how to figure where to cut out an old panel, (say a cabcorner, or floor patch). if i put the new panel over the existing one and trace it can i cut on that line to butt weld or "x" of an inch less? Thanks, Devin

That's close to how I do it. Except I don't cut on the line. I leave a little extra to start fitting the new piece. Sometimes I trim a little off the new sometimes more off the old. Leaving a little helps when doing the hammer and dolly work to get a good fit. You'll probably get more responses if you post this in the paint and body section.

cut your truck's problem area back to good metal and then trim the replacement panel to fit...

What bigvinnie said.I go with a 1/16-1/8th gap.Use small welds,not much more than a tack weld,and space them out.I like to use a flap disc for grinding the weld smooth.To heavy grinding will warp the panel.