I haven't done the hard bit yet, welding it in. It's more a case of learning the skills as I go rather than having them.
I am glad you askedObviously the frame needed some attention before I weld on the outer patch panel, so that was tonight's job.
When I removed the bog there was a big rust hole, you can see in the first picture where I drilled that out and attempted some spot weld repairs which it was pretty obvious was not going to work. So time to make a patch panel for the inner frame and weld it in. the start of the panel (cut to shape) is in the first picture.
Time to start shaping, a small V shaped gutter was the first spot to get the hammer treatment.
Add some curves, a return and a return folded edge and its starting to look something like the piece to be cut out.
Then cut the rusty section out and do the final trim and fit.
Then weld it in and clean up the welds. I have a bit more cleaning up to do on the outer edge. The welds in the top recess I will leave as they are. Its quite difficult to get in and grind them and they will never be seen and wont interfere with the outer panel, so they will stay as is.
After I finish the cleaning up I will sand blast that section and give it a few coats of primer before welding on the outer patch.
Cheers Andrew