Fitting a replacement rear pan/ lower back panel EH.

Again this is a very common panel to have to replace on an EJ or EH sedan. There are a number of extra bits you will need to consider when doing this job. The rear pan has a semi- circular recess for where the original exhaust sits. This can be eliminated when the new pan is put on for a cleaner look. There is also the option of a fibreglass rear pan, and that is explained in another part of this site.

When doing the job of replacing this pan, you will find there will be a considerable amount of inner rust, and if this is not treated, then it will continue to eat away. You can see here where the pan has been pulled down after the original spot welds have been ground back using an angle grinder. A chisel is messy, and can damage the inner panels. I suggest grinding to get the original metal away, then using a chisel just to pry the last bit off. The ends around the corner where the pan meets the quarter panels will need to be cut.



You can see here the new panel ready to fit on. When Mig welding the panel on, you will need to drill a series of 6mm holes to weld through to the inner back panel. Make sure you rust tret the insides before welding the new panel on, and trial fit everything many times. The corners of the fabricated replacement pan will need some patience to make fit perfect, as it is not pressed like the factory one. To make one like that would cost tens of thousands for the die alone.


Here you can see the pan welded on and the weld ground back. These are to later be linished and no filler put in. If there are any holes in the inner pan you will find them easy to replace when the outer is off. Also if you have to replace either of the lower quarter panel sections, then you will need to do them first.

The R/H quarter was rusted a little and damaged around the hole where the bar bolts on. This was repaired before the lower back panel was put on.


The L/H quarter had a new lower section put on, which you will see in one of the other articles. This was done before doing the lower back panel. You can see here where the corner of the replacement panel was cut and rewelded right on the curve to make the fitment just right. It is being a little patient with attention to detail that makes the job look so much better.


Here you see the finished product ready for priming. Only a small amount of filler was required to finish the joins where the replacement panel met the quarter panels.