Made a template for a big repair piece to butt weld in.
Transferred to metal. Awkward shape that uses a lot of steel up.
Required some grinding back to fit. Ended up cutting in half anyway as the bit around the bump stop doesn't fit that great and will need the angle tweaking.
Tacked it in and then I remembered I didn't make holes to puddle weld in on the edge. Drilled some Insitu but did manage to go straight through on some.
Then I also remembered I forgot to change the inaccessible fuel tank bolt. Bent back the lip here and managed to wiggle a fresh one in. I am considering welding this bolt in place but not sure if I'll end up needing wiggle room when putting the tank bank in. I'll also need to hammer down this chassis leg and weld it on. The gap is way too big and whoever replaced the floor didn't do a great job (surprise...). Might have to smack it up from the bottom or even potentially put some steel in-between to weld onto.
Making repair sections takes so long. Even this simple piece took me from 8pm to 10:30pm to plan, cut, prep and tack. Ready made panels that accurately match are much quicker and easier to put in a lot of the time. Many of the panels for this are available and do fit, which is why I've enjoyed doing most of this.
Hopefully this arch is now the worst of it. Not much else that I haven't poked. Only really the inside of the front wing/footwell area on the drivers side.
I'm also debating whether to replace the sill this side. The bottom is pretty thin at the back and I suspect might be thin further along. Big job as needed to both brace and remove the panel all the way along. However now is the time to do it with this wing removed. Pattern sills are £45 posted for both sides.
Or I repair what I have with either fabricating from fresh steel or even potentially cut a replacement sill panel to replace just the worst part on the rear.
Decision, decisions and one that I need to make soon.