Finished about 2/3 of the welding on the window frame today. I managed to retain only a small section of the curved part of the flange that abuts the body frame, the rest is new metal. I’m quite pleased with how this is going, shouldn’t need more than a tiny bit of filler to get the surface fit for painting. Hopefully should finish this frame tomorrow and trial fit before prepping for primer.
6/10/2018
Started to repair first window pan today. Made a new lower flange section and welded it in place, not quite complete yet.
First stage, a few tack welds to hold it in the right position
Then start to weld the seams, spot welds to avoid distorting the existing frame.
5/10/2018
Cleared a space in the garage to start window pan and flitch plate production. Marked up the steel for cutting the first repair sections. I have some 3.5mm galvanised plate for brackets and flitch plates.