Here's another update for you.
As I contemplated what to do about the door, I continued with where I left off on repairs to the bottom front of the rear wing, finishing up the new piece. It fit much better this time.
|Inside tack welds.|
|And outside tack welds.|
I finished the tack welds up, making essentially a long bead and ground it relatively smooth. Then, I clamped it up and welded it in.
|Clamped and ready to weld in.|
|All done getting that part in.|
With that part welded in, it was time to apply some seam sealer. I picked up a tube of Dynatron Seam Sealer from Amazon for about $20. It comes out just like caulk for a bathroom so it applies easily and is spreadable. I wore a nitrile glove while doing this, of course, because it's pretty nasty to get on your skin. It says it's sand-able, but I haven't tried that yet.
|Wow, horrible pic. You get the idea.|
|The end result. I hit a few other spots as well.|
With the inside portion done, I welded the fender lip piece on. Same idea here where I'll tack it until I get a solid bead, then grind it down smooth.
|Not completely finished, but good for now.|
|Initial fit up.|
|It bowed out on me a bit but was easily remedied.|
While getting down there and fitting the patch I noted some more rust-through pinholes, so I cut them out and made a quick and dirty patch for that.
|Small part cut out.|
|The back of the offending part. Always much worse from the other side.|
|New and old.|
|Welded in. Obviously some clean up required.|
And that was about it for the day, it being a "school night" and all. Cheers!