While i wait to buy the new a-post skin panel i moved on to the lower b-post repair. There was some major rust in this area originally and it was one of the first things i cut out when i stripped the car. Its good to be putting something back in!
The repair panel from Sussex Classic Car seemed a good fit and was well formed. I offered it up to the b-post and marked a cut line. I cut 1/2" lower than the marked line to allow some over lap and margin for error.
Some further trimming was needed and i ended up trimming to my original cut line for a flush fit. I positioned the new panel and checked alignment from and rear. I closed the door several times to check the door gap was equal all the way down. The rear of the panel did not follow the arch perfectly top and bottom so i aligned it to match the top and will build up and smooth out the bottom join later. The panel was tacked in place.
5mm holes were made in the door shut flange and these were plug welded to the inner flange. This method meant there could still be some adjustment in the panel, which was needed!
Once securely tacked in place, i seam welded the lower joint; this decision was made some time ago when i decided i want a seamless look on the a and b posts.
Traditionally there is a visible seam here. To avoid distortion, i welded about 1" at a time alternating ends. The top seam was stitch welded, again to avoid heat build up and distortion. Every few welds i closed the door to check the gap again!Door gaps are very important to the finished look of the car!
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