In the end decided to do this in 3 pieces as the paper templates fit nicely on a small sheet of 1mm cold rolled.
And cos I'm a piker!
Traced and cut with the jigsaw, and after bit of work with the hammer/sandbag/press/spanners got this to fit.
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For the next small piece I added a drain hole for all the water that will never come down here. Might put one on the other side too.
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You’d think as I have done one side that things would go easier second time round for the main wing - Nup. Here it is all marked up. 5 folds and a rib - easy.
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So 4 hours later after pressing the rib a second time to get it to line up at the join, and refolding (twice) the main vertical that joins the subframe wall at the top.
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Prepped to weld
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Before I started cutting out the old metal I measured across the sub frame walls - 1052mm. This may or may not be close to what it should be (should have asked), but its what it was and everything bolted together so using a clamp I spread it to that measurement.
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Welding in progress. A few clamps here, but nothing is forced to get the lines right. Lesson learnt from the other side.
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Plugged and butt welded. The original metal is pretty thin so had to chase a few blow throughs. Bit of splatter too which was contamination from the easyphos I put on the metal to keep it shiny. Forgot to wire brush it off.
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