Update from today
Zinc primer is on order, should be here next week and i can start welding in new metal. Don't want to start welding in if i have no way to protect the new bits from rust!
Today has been mostly about cutting out repair patches and cutting the rot out of the car, with the ideal of making nice simple shapes, didn't exactly go to plan! The inner wing was rotten in a strip about 1" along the wheel arch lip, it was pretty obvious that if i was to cut this rot out straight away i would have nothing to use as a reference for new panels. So first things first, out with the cardboard and pencils, trace the arch onto a sheet, cut this line out, transfer the shape to the new galv panels, and cut the shape into the galv;
Obviously its not the arch void (shown above) that i need, but the other side. Some handy work with a craft knife, some more cardboard, back out with the grinder and i had a repair patch. Okay it took about an hour to make this patch but mostly due to a lack of marking implements, almost the second i finished making up this panel i found my marking chalk
Just for reference i'm using 2mm galv panels as it was what i could lay my hands on, and i'm making all cuts with a 1mm cutting disc. I'm then using a metal working flap wheel to tidy the edges (be that remove flashing or re profile to fit).
Anyways this is the repair sections for the outside of the inner wing, comprises a flat plate and a new lip;
I offered these pieces up to the car then tacked them together. Then i dropped the lot, on a hammer, cracked the tacks and they fell apart, bum. But there was enough weld to be able to match them up and re tack them on the bench (which is what you can see below). Having wooden bench i simply battered some nails in to hold the pieces and duly burnt holes in the work top, oops. Just need to bring some steel down to make a welding surface and all will be right!
Now that i had a repair patch with a lip that is true to the original i could start cutting out the rot. I considered leaving the original lip, but that was just getting silly trying to preserve a twisted rotten piece of tin, so it got the chop! This is the top side of the wheel arch hole;
The next picture below is the underside of the same hole, you can see where i have peeled back the stone chip before i go welding, this will all be replaced once the panels are in!
I also tackled the hole in the inner wing panel above the strut. The same repair panel will cover this, but i was concerned about the structural integrity underneath. You can see there is no stone chip in this area, i guess the assumption was that the wheel arch liner would protect the metal. It doesn't stop years of mud and salt getting up above the liner and eating through the paint. Fortunately i've got to it in time and a quick sand back should see it good for the remains of its life. I need to get a suitable brush for the drill to get in there though. Here is said hole;
I finished off the day by making templates for the arch patch to go on the inside. I'm getting good at this cardboard stuff. I've redrawn these templates onto a giant piece of card to aid making up patches for the other side. Hopefully the NS will be a bit quicker, then i can weld the front slam panel back in. I'm happy that the car will be back on the road come Easter, tis not as hard as it looks all this welding stuff!