Yeh I think it was combination of both, until the last one.
Not done a great deal since then, spent most of today trying to get the replacement panel to fit to size, also broke a drill bit trying to drill the plug weld holes. ( It was a cheap and nasty drill bit. )
Anyway here are a few pictures of my efforts.
Welded in the 1.2mm steel I had cut out. Need to do a small repair panel going up the bulkhead by the flitch. It's not the nicest repair but after grinding down it looked ok and the penetration was there. An it's having a panel on top of it anyway so I just put weld through primer on it and left it.
Trying to get the replacement panel to fit.
Reasonably happy with the distance and fit, it needs to be pushed / pulled up a bit here but if I tack it in place and move the clamps I think I will be ok.
Still need to grind a little of this corner to fit , and i'm thinking I will have to replace some of the inner sill as it looks a bit weak at the bottom after grinding it down.
Corner fitting , doesn't look to bad here
I was going to seam weld it on all sides other than where it joins the bulkhead and only plug weld along there.
One thing I did notice was I hadn't removed enough waxoil around the welding when I did the 1.2mm bit , is there a knack to this or just hard work scraping it away...
Edited by tino, 16 October 2015 - 07:18 PM.