Though I didn't end up working a ton of time on the Dodge I did manage to get a lot done in a short time. I only spent about 4-5 hours working on the truck this Sunday afternoon. Its getting close boys and girls! I have both rear fenders pretty much done.....only one left now!
I came up with a pretty good system for the other rear fender....
Step one. Use a wire wheel to get most of the paint off and get down to some bare metal. Its a lot easier to do this step before you get everything cut apart.
Step Two. Use good masking tape ( I like 3M products ) to mark off your cut lines. Use as much as you need to get the cuts you want, mark everything with a pen if you need to remember where to cut.
Step Three. Drill your pilot holes to allow you to make the cuts you need. These go in the eliminated section areas so you don't have to patch anything later. Even with the double section around the fuel filler door I was able to get away with only having to drill two holes.
Step Four. Use this little magic guy to make most of the cuts. The only cut I couldn't do with a the jigsaw was cutting the inner fender away from the outer panel. I had to use a saws-all for this. I used a pretty short metal blade. Cut the inner fender away first before you cut on the outer parts. I had to make this short blade for the jigsaw buy using a cut off wheel on the grinder. This makes the blade just short enough that it doesn't hit the inner panel on the top of the wheelwell.
Make this cut first while the panel is still very stable. I did the horizontal cut and vertical cut in this area while the panel was still in one piece. It add stability and lets you cut without much vibration in the panel.
I then cut the rear section. I cut the panel in one piece with the section attached. It just works out better to cut the sections out once the panel is loose from the truck.
I save the top cut till last. As I go I used some duct tape ( 3M ) to hold the panel as I went. This keeps the panel from falling and ripping the last bit out as you cut it free.
After all that you end up with a big freaking hole in the side of the truck!