Quarter Panel

Complete replacement of the rear quarter panel on a 2009 Aston Martin DB9, including disassembly of rear bumper cover, wheel arch liner, trim panels, tail lamp assembly, and separation of bonded/welded body panel.

Warnings

Tools required

Parts

• Quarter panel (specify left or right side) × 1 — Use OEM specification
• Structural panel adhesive (two-part epoxy) × 1 — Use OEM specification
• Seam sealer × 1 — Use OEM specification
• Wheel arch liner clips × 10 — Use OEM specification
• Bumper cover fastener clips × 6 — Use OEM specification
• Body panel fasteners (various) × 1 — Use OEM specification
• Corrosion protection primer × 1 — Use OEM specification
• Tail lamp assembly gasket/seal × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface in well-ventilated workspace with adequate lighting
2. Disconnect negative battery cable and wait 15 minutes for airbag system capacitor discharge
3. Photograph all panel gaps, trim alignment, and fastener locations around affected quarter panel for reference
4. Raise and support vehicle on jack stands at manufacturer-approved lift points
5. Remove rear wheel on affected side
6. Cover adjacent body panels and glass with protective material to prevent damage during cutting and welding operations
7. Mark body alignment reference points on adjacent panels with paint pen or scribe marks
8. Identify whether quarter panel is welded, bonded, or combination attachment (DB9 typically uses combination of structural adhesive and spot welds)

Procedure

1. 1

   Remove rear bumper cover
   Open trunk and locate bumper cover mounting fasteners inside trunk aperture edges. Remove Torx fasteners securing bumper cover upper edge to body structure. Move to underside of vehicle and remove fasteners securing bumper cover lower edge and wheel arch area. Typical fastener pattern includes Torx screws and push-type clips. Gently pull bumper cover rearward to disengage any remaining clips, then lift away from vehicle. Disconnect any wiring harnesses for parking sensors or lighting if present.
   Torque spec

   Bumper Cover Bolts10 Nm (7 lb-ft)
2. 2

   Remove wheel arch liner
   Locate and remove all fasteners securing wheel arch liner to quarter panel and inner structure. These typically include Torx screws along upper edge and push-type clips around perimeter. Remove the liner by pulling it away from mounting points. Note the position of any wiring or hoses routed through or behind the liner.
3. 3

   Remove tail lamp assembly
   Access tail lamp assembly mounting fasteners from inside trunk area behind trunk trim panel. Remove trunk side trim panel if necessary by locating and removing Torx fasteners and any press-fit clips. Disconnect tail lamp wiring harness connector. Remove tail lamp mounting fasteners (typically Torx or E-Torx) and carefully withdraw lamp assembly from quarter panel. Retain gasket or seal for inspection.
4. 4

   Remove interior trim panels
   Remove rear seat cushion by releasing retaining clips or fasteners at front edge. Remove rear seat backrest by unlatching top retention points and lifting upward. Remove C-pillar trim panel by carefully prying away clips with panel removal tools, working from top to bottom. Remove cargo area side trim panels in affected quarter, noting fastener locations (combination of Torx screws and push clips). Peel back carpet or sound deadening material to expose inner quarter panel structure.
5. 5

   Disconnect fuel filler components
   If working on quarter panel containing fuel filler neck, relieve fuel system pressure per manufacturer procedure. Disconnect fuel filler neck hose clamps and separate hose from filler neck. Disconnect filler door release cable if present. Remove fuel filler neck mounting fasteners and withdraw assembly through quarter panel opening.
6. 6

   Mark cut lines and drilling locations
   Using factory service manual body repair section, identify spot weld locations and bonded joint areas on quarter panel. Mark these locations with paint marker. Typical quarter panel separation occurs along door jamb, rear body pillar, wheel arch flange, lower rocker panel junction, and trunk floor junction. Use a measuring tape and reference points to mark cut lines according to factory body dimension specifications. On DB9 aluminum construction, many joints are structural adhesive bonded with supplemental spot welds or rivets.
7. 7

   Drill out spot welds
   Using an appropriate drill bit, carefully drill out the structural rivets at each marked location on the aluminum body flanges. Typical locations include door jamb flanges, wheel arch flanges, and rear body pillar joints. Count and document the number and type of rivets removed for reference during installation. Use a chisel to separate layers after drilling if necessary. Note: If any rivets are present, center-punch and drill out the rivet heads with the correct diameter bit to release the panel; the DB9 is primarily adhesive-bonded and riveted rather than spot-welded, so follow the OEM body repair manual for exact joint types at each location. Note: Exact rivet count, rivet type, and bonded joint locations for the quarter panel on the 2009 DB9 bonded aluminum spaceframe per factory body repair manual Note: Exact rivet count, rivet type, and bonded joint locations for quarter panel on 2009 DB9 bonded aluminum spaceframe Note: Drill out structural rivets
8. 8

   Separate adhesive bonds
   For bonded joint areas, use panel flange cutter, reciprocating saw with fine blade, or pneumatic chisel to carefully cut through structural adhesive. Work slowly to avoid damaging underlying structure. Common bonded areas on DB9 include lower rocker panel joint and portions of wheel arch. Apply a heat gun to adhesive joints if needed to soften adhesive, but do not exceed the maximum temperature specified in the Aston Martin body repair manual for the bodyshell aluminum alloy to avoid altering temper. Note: Apply heat gun to adhesive joints if needed to soften adhesive, but avoid overheating the aluminum structure. Observe the maximum heat exposure temperature specified in the Aston Martin factory body repair manual to prevent loss of aluminum temper. Note: Apply heat gun to adhesive joints if needed to soften adhesive, but avoid overheating the aluminum beyond the temperature limit specified in the factory body repair manual for the specific alloy, as excessive heat causes loss of temper and permanent strength reduction.
9. 9

   Remove damaged quarter panel
   With all welds drilled and adhesive bonds separated, carefully pry quarter panel away from body structure. Work from multiple points to avoid bending or distorting remaining body structure. Remove panel completely and set aside. Inspect remaining body structure for damage, corrosion, or distortion. Any damage to adjacent panels or structure must be repaired before new quarter panel installation.
10. 10

    Prepare mounting surfaces
    Clean all mating surfaces where new quarter panel will attach. Remove old adhesive residue using scraper and solvent appropriate for aluminum. Wire brush or media blast weld flanges to bare metal. Inspect all mounting flanges for straightness and alignment. Straighten any bent flanges using body hammer and dolly. Apply corrosion-resistant primer to all bare metal surfaces per manufacturer specifications. Allow primer to cure fully before proceeding.
11. 11

    Test-fit new quarter panel
    Position new quarter panel onto body structure without adhesive or fasteners. Use panel alignment clamps to hold in position. Check alignment of all edges, panel gaps with adjacent panels (door, trunk lid, rocker panel), and mounting hole locations. Measure body dimensions against factory specifications at key reference points. Adjust clamping as necessary to achieve proper alignment. Mark exact position with paint marker or tape before removing panel.
12. 12

    Apply structural adhesive
    Following adhesive manufacturer instructions, apply two-part structural epoxy to all bonded joint areas on body structure. Typical application areas include lower rocker panel flange and portions of wheel arch where original adhesive was present. Apply adhesive in continuous bead per manufacturer specified bead diameter. Work quickly as most structural adhesives have limited working time (typically 10-15 minutes).
13. 13

    Install and clamp quarter panel
    Immediately position new quarter panel onto prepared body structure, aligning with reference marks from test fitting. Install panel alignment clamps at multiple points to maintain proper position and gap alignment. Verify all edges and gaps are correct before adhesive begins to set. Wipe away any excess adhesive squeeze-out with appropriate solvent. Allow adhesive to cure per manufacturer specifications (typically 30 minutes to 2 hours depending on product and temperature) before proceeding with welding.
14. 14

    Perform spot welding or riveting
    With adhesive fully cured and clamps still in place, weld or rivet quarter panel at original attachment points. For DB9 bonded aluminum construction, do NOT MIG weld structural body joints. Reattach the quarter panel using structural adhesive combined with self-piercing or solid rivets per Aston Martin factory specification, recreating the original rivet pattern and spacing. Welding bonded aluminum spaceframe joints is not an approved repair and will compromise heat treatment and structural integrity. Recreate the original rivet-bonded attachment pattern along door jamb flanges, wheel arch flanges, and rear body pillar using the OEM-specified self-piercing or solid rivets at the factory-defined pitch per the Aston Martin body repair manual. Spot welding is not the OEM method for the DB9's bonded aluminum structure. Allow welds to cool naturally. Remove alignment clamps only after all structural attachment is complete. Note: Recreate the original rivet pattern along door jamb flanges, wheel arch flanges, and rear body pillar using the rivet type and spacing specified in the Aston Martin factory body repair manual. Do not substitute spot welds for the original bonded-and-riveted joint construction. Note: For the DB9's bonded aluminum body, the OEM-approved joining method is structural adhesive with self-piercing or solid rivets rather than welding; if aluminum welding is specified for a particular joint, use the correct aluminum MIG/TIG filler wire (e.g., 4043 or 5356) and never silicon-bronze. Note: Recreate the original fastening pattern (self-piercing/structural rivets with structural adhesive) along the door jamb flanges, wheel arch flanges, and rear body pillar. Use the rivet type, size, and pitch specified in the factory body repair manual for each joint rather than a generic spot weld pattern. Note: For the DB9 bonded aluminum structure, the OEM repair method is structural adhesive with self-piercing or solid structural rivets rather than welding the quarter panel. If welding is specified by the factory repair manual for a given joint, use the correct aluminum filler alloy (e.g., 4043 or 5356) matched to the base alloy — do NOT use silicon-bronze, which is for steel brazing. Note: Perform rivet-bonded attachment
15. 15

    Seal joints and finish bodywork
    Apply seam sealer to all joints between new quarter panel and adjacent body panels, replicating original factory sealer locations. Common areas include wheel arch inner lip, door jamb edges, and trunk floor junction. Smooth sealer with appropriate tool. Inspect all panel surfaces for any minor gaps or imperfections. Apply body filler as needed to achieve smooth surface and proper contour. Block sand filler until surface is level and ready for paint preparation. Verify panel gaps and fitment of tail lamp assembly, bumper cover, and door closure before paint.

Reassembly

1. Paint new quarter panel and blend into adjacent panels per manufacturer paint specifications
2. Reinstall tail lamp assembly with new gasket/seal, torque fasteners per specification
3. Reinstall fuel filler neck and components if previously removed, ensure all hoses and clamps are secure
4. Reinstall interior trim panels, C-pillar trim, rear seat components in reverse order of removal
5. Reinstall wheel arch liner with new clips as needed
6. Reinstall rear bumper cover, ensuring all clips engage properly and panel gaps are even, torque fasteners per specification
7. Reinstall rear wheel and torque lug nuts to specification
8. Reconnect negative battery cable
9. Perform final alignment and gap checks of all surrounding panels

Verification

• Verify all panel gaps are even and consistent with opposite side of vehicle (typically 4-6mm depending on location)
• Verify door opens and closes smoothly without interference from new quarter panel
• Verify trunk lid closes properly with even gaps all around
• Verify tail lamp assembly seals properly with no light leaks
• Verify bumper cover fits properly with even gaps and no misalignment
• Perform visual inspection of all welds or rivets for proper penetration and coverage
• Check that all interior trim panels fit properly and seat belt anchor points are accessible
• Test fuel filler door operation if applicable
• Perform road test to verify no abnormal noises or vibrations from repair area

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