Find rust, cut, make patch, check fit, trim, check, trim, check, trim, check, weld
Thats pretty much how the last few sessions have gone, props to @mof for hooking me up with some argon, that got the boot floor into place legend!
Gave up searching for 0.8mm offcuts and just went a brought a sheet, that allowed for visible panel repairs to kick off, starting with the drivers front guard
The trailing edge had significant rust repairs, what appears to have been the strategy was cut out the rot and where the frame/stiffener is, just weld direct to that and fill with bog.
Of course this made my job fun, I had to give up on like for like replacement going with judgement and dry fitting to the car.
First of all replaced the rotted section of frame:
Then shape the contour into a fresh piece
Never got a weld pic, but its now securely attached.
Then work on the lower, this got nasty, can just make out the multiple weld lines from donor patches and is pretty rusty/bent to work out where it should be.
Reproduced the lower frame and glued that in after many dry fits to the car
Also see the back edge of the upper patch fixed in place, managed to replicate the folded edge too, very chuffed.
A quick inspection of the passenger guard showed it to be in much better health until I started digging...
While it is relatively rust free, it had the best part of 5mm bog over the whole thing, its been very bent at some stage, beaten about right then filled (with much enthusiasm!)
Full clean up showed quite a mission ahead
Using the better guard as a guide, I sat down with the hammers and various dollys
I've got much better shape now with the larger dents out, but will give it more time, it will need bog but hoping I can learn a few tricks to minimise the amount. New repro guards are near $500 give or take with freight extra so i'll be avoiding that bill as much as possible!
Thats the notable work to date, many more smaller patches here and there in the sills and boot and two more large areas to tackle, most challenging is the rear guard lip, thinking a shrinker/stretcher combo would be helpful here, anyone have experience with them and able to offer advice? The vice mounted Machinery house ones look pretty good value, any reason to double down and go to larger stand mounted ones?