Before fitting the new replacement panel, the attachment surfaces on the wing need to be cleaned up and prepared for welding.
But there are also a couple new simple metal pieces that you need to
fabricate. Examine the old lower panel that was cut away. You can see a
reinforcing strip where the lower, unsupported wing edge (at the front sill
area) meets the edge at the door line. This reinforcement is needed to
prevent a stress crack forming in that unsupported corner.
This piece is made from flat 16g sheet steel stock. A 1/8" bend is formed into one edge to act as a stiffener. Then the strip is curved slightly to match the curve of the wing.
The reinforcement needs to be spot welded to the new lower panel before attaching the panel to the wing.
Another tiny reinforcement strip, also 16g, needs to be made for the front junction of the lower panel in the wheel arch.
Now it is time to trim the wheel arch junction to match the new lower
panel. Trim this to leave about a 1mm gap with the lower panel
positioned for best match with the curve of the wheel arch and alignment
for the door.
When everything is aligned, clamp in place with locking
pliers to prepare for welding.
Rather than plug welding, I did all the welding with TIG, and all spot
welds are a weld-through method with no holes drilled. This method
results in a weld similar in size to the factory spot welds and is
quick. A tiny drop of rod is melted onto the spot and then heated with
the TIG torch until it just starts to penetrate through both layers.
The flanges at the rear edge are folded last. before folding. There are special tools
made for folding the edge, which I don't have. So I just used a body hammer and
bucked the other side over a sheet of wood.
But be sure to redo the 4 spot welds on the folded flange.
This will be the edge visible at the door gap, so take the time to make this straight and smooth.
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