Tantalisingly close now!
I am really pleased with today's progress.
I have almost finished the OS front end, there is just the outer valence repair to do at the top, I'll do both last I think.
Because the front end of the wing was pretty shot I decided to do what I did on RUK again and graft a replacement section on from what would otherwise have been a scrap wing.
If you want to do this then this is how!
I cut the wing in half at the top of the wheelarch, you need to cut the front end of the old wing off first to allow placement. Then you can place the replacement wing over the top of the old, line everything up and decide where you want to cut.
Then all you do is clamp both wings together and taking a 1mm cutting disc cut through both wings, this gets your join line in exaclty the right place with a 1mm gap for the intergrips.
The you can remove the old wing from the car and clean everything up.
Once everything is clean and back to good metal you can mount the wing, adjust the position and clamp the seam with intergrips. Don't thing I'm being patronising here but the secret to good welding is cleanliness, especially getting this seam right.
On this wing I have one swage line that doesn't line up, this isn't the end of the world this can be fixed. The important thing is that the major lines are correct and the wheelarch lines up.
You can see the top lines up...
Then all you need to do is to tack the wings together, take out the intergrips and check alignment.
Once you are happy that everything is aligned carefully stitch weld both wings together. Take is slow, let one area cool down whilst you do the other and check that the panels are still flush with each other, this bit takes some patience. It doesn't look pretty but the weld has penetrated fully and neither panels have distorted.
You can then take a flap disc and flat back the weld. Yes it will need a skim of filler but not a lot at all.
Just need to attach the lower valence, I made a repair section so that both seams would join.
Checked that the bumper fitted and was aligned properly
I just need to dress the welds on the lower valence and create a seam here.
The passengers side wing swage lines do line up properly, it doesn't look like it because they have some filler on them but the metal does line up, this is going to work really well.