TechnicianVision · Knowledge base
Back-To-Basics: Exterior Panel Fit-Up
I-CAR · October 29, 2025
Summary
This article outlines the essential steps for ensuring proper exterior panel fit-up during collision repairs, emphasizing the importance of test-fitting panels before final installation. It highlights key practices such as fitting panels while the vehicle is level with the suspension loaded, using temporary fasteners, and referencing OEM gap specifications.
What to do on the job
Test-fit all replacement panels with the vehicle level and suspension loaded (or on a fixture bench) using temporary fasteners to verify alignment and gaps before final welding or assembly.
How to use it
Use this document to justify the necessary labor time for pre-fitting/test-fitting panels, leveling the vehicle, and loading the suspension prior to welding or final assembly. It serves as industry-standard support showing that test-fitting is a critical step for a quality repair and not an included operation.
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