Some new metal for strength

Finally had some time to work on the car.

I left the car for sometime with the heater channel removed so before I went I added a scissor jack under the door, to stop the opening from spreading. I also spent some time removing the black primer from the new heater channel. With a couple of coats of weld through primer finished off the preparations.

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Now with some time on my hands I was able to get the channel into position. I decided to buy the inner front repair panel due to not having anything to make a pattern from due to the extent of the rust.

Drilling out the spot welds the panel was easy to cut out and the seam on the A post was prised open to release the final part. Cutting out the panel to the marked line gave me plenty of room to adjust the position of the new channel.

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Looking at the bulkhead I need to carry out extensive repairs to the double thickness  area so I will remove the inner part at a later date.

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Tack welding the heater channel, I was able to get it into the correct position.

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Once into postion I started to close up the front.

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And grinding as I go.

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Due to the movement in the car the panel didn’t fully fit so I had to make a filler plate to improve the fit. Once finished I protected the bare metal with oil.

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I ran out of gas for my welder so had to stop.

Next will be time to finished the heater channel fit and A post repair.

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