Okay...

I couldn't actually purchase any of the "power" tools we discussed in my town. No one had any in stock... or so they lied. As I walked thru OSH there was the PorterCable shear that the manager told me they didn't have on the phone.

But taking RJ & CJ's advise I picked up 3 cut off blades, ($1.99 a piece) for my 4 inch right-angle grinder. That worked quite well!!!
The cut-off wheels last a shockingly short time. 16 linear inches of cut. Good thing they're cheap!

It caused very little local disturbance to the uncut adjacent metal. I'm most pleased!!

The hardest part was actually removing the second inner bracing and box structure from the "new" chunk we got from the junkyard without messing up the pristine outer skin. There were 26 spot welds to negotiate.

So today we are going to finish trimming up the new piece to the body and welding it on everywhere. This is going to leave an 18 inch weld line up the side of the quarter panel.

I presume the bead will stick out a little and will need to be hammered in a bit. Once done with this I guess we will need to fair everything with bondo?

I have never used bondo before... the can has almost no useful information on it. What tips can you guys offer on the subject, keeping in mind what specifically I'm bondo-ing..