Front Window Repair

The corners of the passenger window had rust.  I used some of a side window to fix it.  The side windows are wider, but of similar curvature.  the hard bit is the grinding down of the weld on the curve.

Front Cab Roof

Today's work included the wheelwell and cab roof. The cab roof has some of Morrow's original metal as the Zebra's was dented. The funny pink thing is a fake halloween scab.

Rear Right Wheel well

The bottom of the wheel well was bent and rusty so I've added a nice straight piece to it which the mudflap will attach to.

MudFlap

I decided to save the original mudflap.  I gave it some rust treatment and welded it up.

Rear Right Lower Corner

I had a busy couple of days. I started around 9 each day so as not to annoy the neighbours too much and because it was faily cool. 46F at night.


I have not had the motivation over the summer due to it being so hot and because I thought we were moving to better premises. 

At Bulli Brigade and Bug Jam I sold lots of camping accessories and then I bought panels from Gerson. 

The new panel on the rear corner will not be welded on until the battery tray is welded, which will have to wait until more panels arrive.

passenger dog lower rot repair

Lower Nose

Don't know if I needed that many welds but the panel shouldn't come off for even in an accident.

Front Outer Valance

Inner valance has seam sealer applied.  Outer had holes drilled then plug welded.  Also flanged the old nose to fit the lower nose and sprayed some foam to fill empty wire holes.

Front Valance

Inner valance went in fairly easily.  The outer one is harder to line up to be correct at the left and right hand edges.

Inner Valance

The inner front valance fits behind, over and below the A Pillar repair panel. I welded on the valance first then the remaining piece of the A Pillar.

Lower B Pillar

I see some people weld the green pieces together and then attach it in one piece. I'm welding in each piece separately. I left some of the old metal and also welded on a tab so the welding would be stronger.

B Pillars

First thing is to figure out how these three pieces fit together.

Front Valance

Don't forget to order new lower A Pillars as these will probably be rotten too.

A Pillars and inner valance work

A Pillars need replacing. Cutting away the metal that attaches to the end of the frame is a chore. I may end up trimming the new panel instead.

lower nose repair

Peeeling away the metal layers