When I took out the rear panel, it was pretty disappointing to see what they had done to the part. Like the inside quarter panels, it was incorrectly installed and was clearly not a new piece as advertised. This is what I started with:
And what was done to it because the didn't fit it properly:
The lower panel was not salvageable but the top panel looked like it could be reused. However, it was bent and warped at the connection of the two panels so that had to be dealt with first. Pulling off the leather, foam and padding left this:
After figuring out how to re-shape factory door pockets (more on that later), I used the same technique to flatten and square the mounting flange for the lower panel. Using the work bench for one surface and a 2x2x1/8" aluminum angle for the other, I clamped the panel like this:
Then, carefully and uniformly heated the portion of the panel to straighten with a heat gun to 280 F - 290 F while closely monitering the temperature with an infrared pyrometer. Any hotter and you will melt/damage the panel, any cooler and it will not assume the new shape. Finally, let it cool to ambient on its own. If it cools too fast (like using compressed air to accelerate the project, warps come back). It took many tries with the door pockets to figure this out!
To match the carbon fiber panels on the inside of the quarter panels, I was planning on running a band of carbon across the face of the rear panel. The panel had to be perfectly flat or the carbon would show the distortion. I sheared a length of 2x1/8" aluminum bar and glued and riveted it to the back of the panel. This reinforcement would ensure the mating flange stayed flat. Came out like this:
Then cut aluminum panels to fill in the speaker cut outs and covered the aluminum inserts with foil tape to conceal the lines of the infill.
Time for a test-fit
Was pretty happy with the fit so now it was time to make a new lower panel. Ok, outta pic allowance so will continue in the next post!