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**roy mawbey** · 02-16-2021, 05:53 PM

Thats a great bit of work Scott !! Well thought out.

Roy

**Scott B** · 02-17-2021, 02:55 AM

Thanks Roy.

So made up a jig to hold the filler extension and gas cap to position the four hole grab handle. My buddy bronzed it on and a little clean up and grinding the seam - turned out well. Next trick was to figure out the height and angle of the filler neck extension. Took some math and challenges to cut the angle and then sneak up on the height. I think I am going to go with the gas cap flush with the hood. I have seen examples with it sitting lower.

**Scott B** · 02-17-2021, 05:39 PM

Settled on final position and angle of the filler neck. Magnets and a couple of tacks to hold it in place and then bronzed around the lip.

**Scott B** · 02-19-2021, 02:10 AM

Need to focus on the rear now. Will be replacing the rear with a Trevor panel. First job is to address rust issues on the rear lid. Some of the pin hole rust spots are to tough to weld with a mig. Just blows through the lacy thin metal. Fabricated a piece for the worst section.

**Scott B** · 02-20-2021, 04:23 PM

Finished up the rain tray - using a dog bowl - cut hole and slide on a rubber u channel for snug fit. Moulded a bit of a curved lip in metal with a press.

**Scott B** · 02-20-2021, 11:03 PM

Starting to tackle the rear end. I was really tempted to cut in the full new panel but I think it would be more work then itâ€™s worth. Found a compromise just out board of the bumper indents. Started to cut off some off the excess off the new panel. I didnâ€™t like the profile of the rain gutter lip either - to shallow and not deep enough so I have decided to not use this. This may be a problem down the road as I wonâ€™t be able to dolly the weld seam but saves a lot of effort in drilling out the old gutter and reshaping the new gutter.

**Scott B** · 02-20-2021, 11:05 PM

Early fit with first cut on the sides of the new piece and the gutter cut off. Worked to get this centred around he existing light holes.

**Scott B** · 02-21-2021, 04:48 PM

Started to tackle the rear with removing some of the old metal to start sneaking up. Clecos around the gutter and then pinned it to the rear brackets. There is a lot of extra material here on the new panel. I can get it close with lots of clamps but a lot force. I think I may have to slit the new panel. Not sure yet.

**Scott B** · 02-22-2021, 04:35 PM

Thanks Justin - and great to hear your written voice again. Was getting worried I hadnâ€™t seen you post in a while. I hope all is good and you are keeping safe and healthy.
So I ended up slicing through the original seam. The metal needed some shaping a bit as the curve was more than needed. I then clamped it back on and allowed the two piece to overlap in position. I then tack welded the pieces to together and then took little slices out to butt seam and weld slowly up. I think I have gathered enough metal up to make the left side work now.

**Scott B** · 02-23-2021, 05:46 PM

Right split then rewelded. Fitting better. Edges joggled to revive new panel.

**Scott B** · 02-24-2021, 04:20 PM

Panel all prepared and in final position. Tacked in place - no turning back now - slowly welding trying to control the heat.

**Scott B** · 02-25-2021, 02:27 AM

Weld and grind and dolly. Weld and grind and dolly. And repeat....and repeat. Some hours ahead.

**roy mawbey** · 02-25-2021, 12:23 PM

Scott, well done on this work. You have done so well and its a really neat job. You are making it look easy just like Justin does! I also am pleased to see his recent comments!!

Roy