10mm out

So depressing day today. Lots of work will need to be redone, because I didn’t take enough measurements along the way when reassembling. Here’s the low down.

Cut the repair panel out of the sheet. Very little fine tuning needed to get it to fit. Welded that in…

Realised that I hadn’t ground down the welds on the other side in the wheel arch and so went back and did that side to match.

Having done that spent a couple of hours tweaking the tabs on the boot floor reinforcement channel and also joggled them with a BFH so that they fit properly underneath the cross member. After that primed them up and then had a look at another job on the list, repairs to the repair panel for the near side inner rear arch.

The three vertical pressings give a really good key for positioning. Off side looking good… So how about the near side?

Erm… significantly more poke of the inner 1.6mm plate showing out from the overlaid panel. This is not right. Comparison again the OEM panels confirms this – there’s a little bit of bike but there should not be that much!

So back into the interior and taking a load of measurements and the nearside has too much negative angle and will need to addressed. Drops 10mm over the distance of the cross member end plates.

Should look like this.

So better to have caught the issue now rather than have done more reassembly before realising but there’s still a load of chopping out to do to get back to a position of being able to correct it. Time for a beer.