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1966 Deluxe 21 Window Shamba
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Mr Margaret Scratcher
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PostPosted: Sat Sep 25, 2021 1:44 pm    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

More digging:

D Post outer removed:
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These pics are for my reference:


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I'm going to attempt to repair the post, hopefully without having to remove any more metal. It's a little pitted though as you can see from the first pic, so we shall see.

If it turns out to be too difficult, Alan Schofield here in the UK sells a D post for 63 and up buses, which is actually the same as for early bays:


Image may have been reduced in size. Click image to view fullscreen.


Does anyone know if that bulge sits against/is welded to the rear corner panel?
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Mr Margaret Scratcher
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PostPosted: Mon Oct 18, 2021 9:27 am    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

So inspired by an excellent thread over on the RetroRides forum:
https://retrorides.proboards.com/thread/70135/panels

I started attempting to make the inner half of the D post:
Image may have been reduced in size. Click image to view fullscreen.


Seems alright, maybe I can do this...
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Had to bend this return lip with molegrips:
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A couple of measurements:
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But overall pretty happy with my first attempt at making a panel:

Image may have been reduced in size. Click image to view fullscreen.

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Mr Margaret Scratcher
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PostPosted: Mon Oct 18, 2021 10:30 am    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

Carrying on, wanted to avoid using the mole-grips to bend the return lip on the other side, so was initially going to try to use a dolly to tap it over where it needed to bend (clamped in between the pieces of angle iron):
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But in the end, just pushed it over by hand:
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And then tightened up the bends where needed using a hammer and dolly:
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Also used that to flatten out the kinks left from bending with the mole grips:
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This is the contour that the post had:
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Traced onto the panel:
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Rather than try to shrink the metal to get the angle, I decided to cut along the edge and bend the lip down:
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And then I'll weld that up.
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Mr Margaret Scratcher
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PostPosted: Mon Oct 18, 2021 10:41 am    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

A bit of straightening on the splash panel:

Before:
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During:
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After:
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Still some further tapping to be done, but I just wanted to evaluate whether I'd be able to re-use it, and I think that I can...
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Mr Margaret Scratcher
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PostPosted: Mon Oct 18, 2021 12:55 pm    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

Continuing on hacking out the rot.

I wanted to save this little bracket that the D-Post attaches to, as it doesn't seem to be available anywhere (Although the KlassicFab D-posts have it attached, but seemingly not available on their own)

Image may have been reduced in size. Click image to view fullscreen.


You can see that the rear valance bracket has trapped a load of dirt in between it and the rail:
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I poked as much of it out as I could:
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I was going to try to save the engine gusset triangle webbing support part, but it would have required repairs:
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and so I weighted up the extra time to remove it without further damage, plus the time to repair it vs £25 or so for a new one. Guess which option I went for?

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Although solid, the corner seems quite pitted above where the tray was:
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That, combined with the state of the tray (non-existant) and the mud in the rails makes me wonder if the bus was submerged in mud for a while, or maybe just had the tray full of water for long enough until it rusted through.

Test fitting the tray:

You can see a little bit of light where it doesn't quite butt up against the inner side:
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Here I was trying to figure out if the tray was going to clear the engine side metal:
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Still not sure. Also looking at the other side it seems like maybe I should have the lip that runs along the edge of the tray separating it from the engine bay.
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Mr Margaret Scratcher
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PostPosted: Mon Oct 18, 2021 1:04 pm    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

Last piece of the engine bay web bracket removed:
Image may have been reduced in size. Click image to view fullscreen.


D-post Support piece removed:
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Which gets us here:
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Now to cut out the pitted metal from the engine bay side panel:

Marked:
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(This gets cut at an angle to clear the rail beneath)

Zipped out with a cutting disc:
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This was more straightforward that I expected.

Pinholes:
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Transferring the pattern to a piece of fresh steel:
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Test fitting:
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Mr Margaret Scratcher
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PostPosted: Sun Oct 24, 2021 1:18 pm    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

Decided to add in the slight indent that the edge of the battery tray sits in.


A bit of angle iron with a piece of sheet steel clamped to it:
Image may have been reduced in size. Click image to view fullscreen.


Lay the panel on top, being sure to make sure you're bending the right piece down:

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Use a BFH with a chisel that has been blunted slightly:

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Et voila!

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Also used some pliers to bend this corner slightly:

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To fit in here:

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A bit of Bonda to protect and that finished this update:

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Mr Margaret Scratcher
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PostPosted: Sun Oct 24, 2021 1:19 pm    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

So today I decided to break out the welder and attempt to let in that panel, but first I had to make the slight step on the existing metal of the engine side panel match the panel I had made:


I jacked up a block of wood with a dolly and a piece of sheetmetal on it:

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Then used the blunt chisel and the BFH from the previous pics to make the slight step.
Much better:
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Tacked in place:
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Fully welded:

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Cleaned up...ish:

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My welding seems very inconsistent, but I realised the one thing i've not been paying attention to is my angle - I think I was holding it far too shallow.

It can only get better from here though, theoretically!
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Mr Margaret Scratcher
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PostPosted: Mon Mar 28, 2022 5:14 am    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

So the combination of the clocks going forward an hour combined with the weather getting nicer again here in the UK means I'm jumping back into this again.

I Just tried to place the inner engine bay web bracket piece where it should go and it seems like the hinge bracket is in the way:

Image may have been reduced in size. Click image to view fullscreen.


Is it that these are generic and need chopping down for certain years?

This is the area, for reference:
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(I've separated this into its own thread here: https://www.thesamba.com/vw/forum/viewtopic.php?p=9830701#9830701)
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Mr Margaret Scratcher
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PostPosted: Sun Oct 16, 2022 1:43 pm    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

Moved house, now have a garage (Not that there's space in there at the moment to put any of my vehicles), but I've been inching forward a little:

I wasn't feeling fully confident that my attempt at fabricating the D post was going to be successful, so in the end I contacted Klassicfab to try to locate a D pillar (I couldn't find any in stock in the UK)

It arrived, but unfortunately wasn't correct - I think the D pillar changed towards the end of the split production. Here it is next to my WIP attempt:

Image may have been reduced in size. Click image to view fullscreen.

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You can see that the newer style D pillar is a two piece box section type affair, whereas the older style is a single layer.

So I decided to crack on and see how well I could do after all, first port of call was trying to make this little bracket which I couldn't find for sale anywhere:
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(I attempted this twice - I had to start over because my welds weren't penetrating and after grinding them welds back a few times I'd just made the metal too thin)

Easy part:
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Tricky part:

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Sliced:

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Filler piece:

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Filler piece wedged in:
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Welded to the rest of the bracket:
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Painted with bonda:
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Clamped up the inner D panel with the engine web bracket:

Image may have been reduced in size. Click image to view fullscreen.


Next step it to cut the rear corner up a bit higher without cutting through the post so that I have space to weld the post in
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Mr Margaret Scratcher
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PostPosted: Fri Oct 21, 2022 5:22 am    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

So I was kind of umming and ahhing, and knew I wasn't happy about this gap between the little bracket and the D post contour panel:

Image may have been reduced in size. Click image to view fullscreen.


Comparing the little bracket to the opposite side showed me that the bracket itself was spot on in terms of size etc, so I knew my self fabricated D post was off.

I then realised that with the engine bay web and the little bracket in place, I had a curve to go off:
Image may have been reduced in size. Click image to view fullscreen.


So what I did was cut off the curve and tack welded the post in place:
Image may have been reduced in size. Click image to view fullscreen.

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Clamping the engine bay web and the bracket in place, I then used that to tack on a thin strip of metal to the D pillar:
Image may have been reduced in size. Click image to view fullscreen.

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When I was happy with that, I cut through the tack welds so I could weld the strip along the edge and clean it up, then weld it back in properly:
Image may have been reduced in size. Click image to view fullscreen.


We'll see how well this cleans up:
Image may have been reduced in size. Click image to view fullscreen.
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Mr Margaret Scratcher
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PostPosted: Fri Oct 21, 2022 5:30 am    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

I then did the same on the outer D pillar - cut off the lip and clamped it to the inner pillar, and then tacked the lip back on with it pressed against the contour that I was happy with in the previous step.
Image may have been reduced in size. Click image to view fullscreen.



I then welded along the edge properly and cleaned it up with a grinder, might have to go in a do a bit more:
Image may have been reduced in size. Click image to view fullscreen.

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This will be hidden underneath the edge of the corner panel, but at the same time needs to be tight enough of an angle to let it lay flat, so we'll see...

Also, this edge needs knocking down a bit, as it was kind of hard to bend with the lip already on it:
Image may have been reduced in size. Click image to view fullscreen.


Once I'm happy with all that I can get it welded on!
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Mr Margaret Scratcher
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PostPosted: Wed Nov 02, 2022 4:55 pm    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

Ran out of welding gas, but decided to cut/bend some metal to make my corner repair piece.


Empty cylinder makes a decent pipe anvil:


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Pretty happy with matching the curve:

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Along with the edge and the lip piece, I now had a DIY rear corner repair panel!

(Some assembly and trimming required)
Image may have been reduced in size. Click image to view fullscreen.


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Image may have been reduced in size. Click image to view fullscreen.
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Mr Margaret Scratcher
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PostPosted: Mon Dec 12, 2022 4:32 pm    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

Starting the inner D-Post Clean up:
Image may have been reduced in size. Click image to view fullscreen.


Inner engine bay web welded in:

Image may have been reduced in size. Click image to view fullscreen.

(My plug welds seem to be standing a little taller than I'd like, any pointers would be gladly received)

Battery tray finally welded in!


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I didn't get any pics of the welds along the edge as it was dark by the time I finished. Also, not to self - don't try to weld in the dark...)

Outer D post plug welded along one seam where it meets the inner post, and butt welded along the join:

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Image may have been reduced in size. Click image to view fullscreen.

Still pretty happy with making this repair piece myself, even if it is a little bit wonky!

Next I made some holes in the thin strip that will be the inner lip of the rear panel repair piece so i could cleco it in place:

Image may have been reduced in size. Click image to view fullscreen.


so I could tack the next part of the DIY panel in place:

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Image may have been reduced in size. Click image to view fullscreen.

I'll weld this all up and then the next step is weld the curved section of the body to it...
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SplitBusVanatic
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PostPosted: Tue Dec 13, 2022 5:38 am    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

You've come a long way from where you started.
The clecos' arrival on the scene make you look so professional. HaHa
Keep up the good work.
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SplitBusVanatic
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PostPosted: Tue Dec 13, 2022 5:45 am    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

BTW
Great thread that you linked on retro rides,
Thanks for that

https://retrorides.proboards.com/thread/70135/panels
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Mr Margaret Scratcher
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PostPosted: Tue Dec 13, 2022 5:58 pm    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

SplitBusVanatic wrote:
You've come a long way from where you started.

Yeah, I'm really happy with the progress I've made this year, especially in the last couple of months - it's a combination of studying threads on here, things like the retrorides thread and also just giving it a go. Attempting to make the panels that weren't yet attached to the bus was a good, low enough stakes that I didn't worry (I could always just start again) but high enough stakes in that I had to actually make a part that fit well and looked half decent.

SplitBusVanatic wrote:
The clecos' arrival on the scene make you look so professional. HaHa

Hah, yep I think I'm ready to go pro!

SplitBusVanatic wrote:
Keep up the good work.

Cheers!
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Mr Margaret Scratcher
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PostPosted: Tue Dec 13, 2022 6:04 pm    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

SplitBusVanatic wrote:
BTW
Great thread that you linked on retro rides,
Thanks for that

https://retrorides.proboards.com/thread/70135/panels


Cheers, also highly recommend https://youtube.com/@fitzeesfabrications
The guy's fabrication skills are amazing and he does it all without using any fancy tools.

Check out this cut 'n' butt technique to get perfect fitting repair pieces every time:

Link
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Mr Margaret Scratcher
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PostPosted: Tue Dec 20, 2022 1:55 pm    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

Made a bit more progress today - getting the main curved section attached to the edge and lip:


Clamped in place
Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.


Tack welded to attempt the cut n butt method:
Image may have been reduced in size. Click image to view fullscreen.


Edge tacked in place:
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Panel cut free:

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Outer tacks: Confused
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Inner Tacks:
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Inner stitched:
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Outer Stitched:
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(It's obvious from this pic that the tacks weren't making it right into the corner, more on that in a sec...)

Edge dressed up:
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(You can see a line where the outer tacks hadn't penetrated into the corner to join both pieces of metal)

Test Fit:
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There was a large gap between the edge of my curved panel and where I'd cut into the corner piece, I assumed that might be from the weld on the inside of the repair piece sitting against the D post and shifting it over toward the engine bay, so I tried to use a grinder to dress the inside of the edge
Image may have been reduced in size. Click image to view fullscreen.


However, I accidentally ended up almost grinding through the curved panel next to the welds Embarassed
Image may have been reduced in size. Click image to view fullscreen.


I'm going to try to see if I can salvage it, starting with re-welding along the outer edge:
Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.
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Mr Margaret Scratcher
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PostPosted: Sat Jan 28, 2023 9:51 am    Post subject: Re: 1966 Deluxe 21 Window Shamba Reply with quote

So I *thiiiiink* I managed to rescue it:


Image may have been reduced in size. Click image to view fullscreen.


Where I dressed the welds along the edge I seem to have taken off a bit of material from the face of the panel so if you look along it you can see it curves down slightly, but I think with a skim of filler it should be alright.

Quick update from today - got the engine web bracket in and welded, along with some plug welds attaching the two halves of the D post together:


Image may have been reduced in size. Click image to view fullscreen.


Just got to weld the seal retaining strip together (awaiting a bit of copper to do this), clean up a couple of welds along that channel and then I can attempt to weld in the corner repair piece, which will be my first externally visible (well, hopefully not) repair... Shocked
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