Sure some have run into this dreaded repair. Mine seemed pretty mangled, but wasn't so bad. I guess this is common when certain carbs are fitted to the A-series. I thought the return would be way to difficult to get looking correct, but was happy with the result. After some filler and final shaping, should not be very noticeable.
Basically, kept what was good and tried to keep some points of reference, traced out the missing piece and used an adjustable spanner to slowly bend the return, plus a little hammering and hand bending.
Mangled mess
left extra to help with the spanner bend the return and clamping of the repair piece
clamped
welded in , kept the welding to short pulses and spread it out untill it all connected to keep the warpage to a minimum
ground back and temp sprayed some weld through primer on
This is probably the most complex repair I have done, and it wasn't too difficult. I just took my time and went for it and glad I attempted the repair. Had a few other bodge jobs to fix in the vicinity and I am happy with how the bulkhead is turning out.
