The AMD panel is a virtual match for
the original, so up to about an inch
of overlap will cause the new part to
mostly self-align against the old.
When its correct position is confirmed,
it should be firmly clamped in place.
With the new part clamped to the old, a
saw (or cut-off wheel) is run through the
overlapped area to trim both parts and
to leave a perfect gap for butt-welding
the two together.
Here’s approximately the max amount
of overlap that should be allowed.
There needs to be enough to make
a clean cut through both panels, but
too much can hinder proper fitting of
the new onto the old.
After the wheelhouse is generously
trimmed and blasted to remove the
e-coating, a final cut line is determined
that will leave an adequate overlap over
the original panel.