Despite what you might think, not all vehicles are equal – which is why trial fitting parts before you paint them is so important.

There’s nothing more annoying than getting a brilliant finish on a replacement body panel only to find it doesn’t fit quite right or it needs slight modification to go on properly. That’s why you should always dry fit first…

Despite manufacturers such as Volkswagen working to exacting standards, it’s not unusual to find dimensions vary to a tiny degree – and then there’s the minor spec changes manufacturers make without really telling anyone. Even within the same model year, or month – the shape, design, construction and fit of some body panels may vary slightly. Bear in mind too, unless you’re lucky enough to own an entirely original, previously untouched classic, chances are the vehicle you are restoring will have had all manner of work done to it in the past and this can also affect how well a brand new panel fits.

Which is why it is crucial to offer up any new or repaired panels or repair body sections to your vehicle before you begin the final rebuild. Even the best quality panels may need some fabrication to fit properly, be that trimming, ovalising bolt holes slightly or carefully reprofiling their shape with a small amount of filler. If you refitting the original panels like wings, for example, mark them up as you take them off so you can bolt them back on in the same place later on.

If you try the panels, make any necessary alterations, then trial fit them again before finally repainting them it will prevent lots of swearing and result in a far better end finish. You can do the same with trim and items such as wing beading. Trial fit before you ‘do it for real’ with a shiny, freshly painted panel to avoid losing your cool if it doesn’t quite all go together as you hoped.

Of course there’s also the vague possibility that you’ve ordered the wrong part in the first place and if you discover this during the dry fitting process, it will give you the opportunity (assuming the panel’s not been altered or damaged in any way) to swap it for the correct part.

Like most aspects of a rebuild, if you take your time, do it properly and resist the urge to rush things the world suddenly becomes a much better place!

Ian

The opinions expressed here are the personal opinions of the author and do not necessarily represent the views and opinions of VW Heritage