Today we started off by putting on both fenders, front bar and bonnet, and had some toast.

Before:

After:

With the panels, we were able to bolt down the bonnet and align everything. This was because the next piece to weld in was the threaded piece for the bonnet on the passenger side.

It was clamped in place whilst algining and then I cranked up the amps and pumped the weld into 2 spot welds on the piece. The top one which you can see below was there from factory, the bottom one we drilled ourselves. The top one was the only one we saw when initially removing it, no idea what else held it down apart from the layer which goes above.

I did not want to take any chances with the bonnet flying off whilst driving. I'm still contemplating welding around the edges of it before putting the piece over it.

With this sorted my dad starting working a piece for the top of it, whilst he did it as it's a 1 man job I started on this, well horrible previous rust repair job by someone in the past, on the drivers door jam.

My plan was to grind the aids back to level with the body and assess how bad it still is, as the door stopper piece is still quite solidly welded in there. Theres still some weld inside which has surface rust which the grinder won't reach to. I can either weld up some the holes around it to clean it up and leave it, or cut it all out and do again.. Still unsure what to do as there are 2 layers there.. It's not pretty what so ever, and I think in the end it'll all be cut out and re welded.

Also grinded back this surface rust under the door hinges

And so this is where we are at, this is will cover the lower part, with a seperate piece to cover the upright. They will obviously be welded together. To make 1 whole piece seemed kinda tricky so dad thought this would be an easier method.

The weekend after I returned to weld in this piece. Writing this post in 2023 now (a tad behind), man these welds look horrible, might have to revisit them in the future. Started off with welding in the side holes, then trying my best to weld up the rest of it without blowing through the metal.

The lowest hole we welded a nut to the back of it for the fender as well.

Once done we started to mock up the top piece using some paper to try and get the required shape which turned out to be a tad tricky with the curve on the crowl. Also checked how everything was looking with the crowl and hinge temporary on the car.