The U-section between the chassis rail and the inner sill on the left side came next. I'd had the three replacement sections made for a while, but this was one of those cases where the closer I got everything together, the more work it needed - trimming with the angle grinder in this case. I started off with a couple of tack welds, then tapped with a hammer here and there, then a few more tack welds, and then I could lay in some seams.
Note to Self: it's much better to attempt welds in cramped surroundings in the morning, when not tired, and when it's not hot and 95% humid. Must be late January in Sydney.
The door seal retainers at the bottom of the doglegs are next. I folded a 3/4" piece of 1 mm sheet into a right angle, and began the main bend: hammering one flange while gently forming the curve, all the while "extruding" the section out of the vice. But then there's a curve in the other plane. I used the dogleg itself as the form, and got out with the tucking fork to pucker the metal, and hammered it down sort-of flat. Trim to shape, notch for plug-welds, and -
Driver's side still to go.
Rob
