Following on from yesterday, I made the patch panel for the upper part of the bulkhead seam repair panel. Then prepared both faces of the joint with zinc etch primer.
Once it was dry, marked the sections for the spotwelds and ground off the primer in the appropriate areas:
Cleaned up the surrounding metal work and welded in the patch. Really difficult spot to work in as it was hard to get close enough to see what was going on properly.
Penetration was good, but I went off line a bit. After this photo was taken I laid some extra welds in from the footwell side to make it good.
Used a number of different tools to clean the welds back. This shows them mostly tidied up. It just needs a little bit more finishing.
With that in place most of the day was spend making the chassis rail top. What a mission! It’s a very complex shape and was difficult to fabricate up. There was a lot of work in both cardboard and steel to get to this.
End point for today. This is the panel ground down and ready to prep for paint and fitting.
Rallye Project 
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