Well I finally got a replacement drivers side fender for the mercedes. Easy, about 12 screws and an inch thick seam sealer, and 6 man hours. They don't say "made like a tank" for nothing. Well after this endevour I was wondering what is the best way to store auto sheet metal so you don't destroy it?
I might be able to get other sheet metal off the car so I was wondering . . .
What is the best way to cut sheet metal off a car? I have a compressor with a small handheld disc grinder, but it is a little large of a setup to bring. I also have an angle grinder but the stone looks too large to cut sheet metal without distorting it. I've never done this sort of thing before but the guy who is parting the car is cool and I have a couple rust bubble so what could I lose.
I would appreciate any insight thanks folks.
I use a 4" grinder and a Makita cutoff wheel. The cutoff wheel are about 1/16 thick and go through sheet metal like a hot knife through melted butter.
Plasma cutter, even the cheaper ones can easily handle car body sheet metal. They are cheap enough now to get a decent one without breaking the bank and once you have one, it is one of those tools that you wonder how you did without.
Chris Rummel
Plasma cutters are cool. A plasma and a tig are the last two tools needed to complete the garage. I have to get my dad to teach me tig, an artform.
I think the makita with a cutoff wheel fits the bill perfectly.
Thanks for the tips folks,
GRM had an excellent metalworking tools/equipment article in the current issue, IIRC
Don't forget the old standby recip saw. The blades can be cut down with a whizz wheel making the saw easier to use in cramped quarters, or you can stick in a 10" blade and whack a car in half. The rechargeables are great for going to the junkyard. Or for stealing catalytic converters at the local car dealership for a little extra jingle in your pockets. 
Or a sheet metal nibbler and a cordless drill. Eastwood sells this one.
Great suggestions. I'll have to check out the nibbler, if only because I like the name.
I'd like to give the sawzall a second change. I don't have one yet. The only issue with the sawzall is if the blade dull and catches the sheet metal it will beat it up. Great idea about getting a fresh catalyst for my car, just in time for smog! I can get an aftermarket cat for 120$ installed so maybe not.
Thanks again!
In reply to Jensenman:
I have that very nibbler, very nicely made in England too.
Chris Rummel
