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Did a rust repair on Ol' Rusty passenger A-Piller using the MIG to do a fair bit of the filling.
http://www.fbekholden.com/forum/viewtop ... 8&start=99
I reckon I have had at least 4 goes at it and every time I grind and sand I end up with another hole or two. So after doing a bit of reading I came across this awesome resource. Making Panels..... https://retrorides.proboards.com/thread/70135 So many great tips and ideas.
Figured I'd have a go at a test replacement patch for the mess of weld.
Life was made a bit easier as I have a repair A-Panel outer for the drivers side. So marked it up roughly on a bit of 1mm cold rolled that I hadn't practiced welding on yet, using the back as a guide as I am going to mirror this piece. Started hammering. As you will see, I ain't got no hammer and dolly set, and my vice isn't the biggest but I adapt and use what I can find. First dolly is an angle bracket. Vice grips to get a more defined edge. Found a solid bit of iron to use as a dolly. Starting to take shape. But hang on - turn it 90 degrees and its the same as the A-Pillar patch panel. Damn, so much for mirroring it!. At this stage I figured this is a test so keep going. Use my gal pipe dolly to get a bit of curve in the hump

At this point its starting to look ok so I gave it a wire brush to get the surface rust, adjust my curve and used a blunt cold chisel to get more definition. Gives this. And the other side. Starting to take shape. Trying to get a bit more definition. Bit of flat bar with a slight radius in a clamp to make a 'hammer' Couple of measurements for the channel. Quick check.

Mark up lip and cut. Left a bit big so I can cut down to the same height as the exiting channel Start to bend up with vice grips Second pass. This bend is forcing a nasty curve in the piece. Compounded by the fact that the A-Pillar curves a bit the other way. Time to use that gained knowledge. Stretch the bend over lip by hitting it repeatedly using the thin flat end of the hammer over my 'anvil' That was 2 passes. Took about 6 passes to straighten it. Another 4 to force it to curve the other way. You can actually feel it releasing the bend as you hammer. The metal on the lip was about 0.8mm by the end

The final result. Pretty happy with it - going to look better than my weld up. At least that's the plan. Too hot to weld it in. 40C in the shed.

Good stuff Scott. You're on to it.

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nice work - you have a lot more patience than I do , I would just wander up the back with a cordless grinder and cut one out of a wreck .......

Great work Scott. Good skills to have.

Nice work Scott