Driver fender continued.
This is the final result of Naval Jelly treatment, this represents 5 treatments. All of the rust has been dissolved from the pits, this is after zinc phosphate has been removed with a wire brush.
Painted the brace with an epoxy paint.
I tack welded the patch panel in a few places and installed the fender to check the contour. From the crease upward the fender matches the door perfectly. From the crease downward the patch panel does not match the contour of the door. I will correct this by using All Metal to get the basic shape.
Removed the fender to finish welding. Tacked welded.
The joint welded.
The weld bead trimmed with a cut-off wheel.
The completed weld. Door side
There is a little misalignment along the green lines. The amount is about the thickness of a Business Card. This occurred because I didn't have access to the back of the joint due to the inner brace being in the way.
I got the instrument housing ready for paint prep. This is result of solvent welding the two pieces together. The housing broke with a crack from the green arrow to the corner of the AC control opening.
The bar was broke at the bottom of the AC control opening
It repair looks good. After being painted the former breaks won't be visible. The housing gets a glossy black finish before chrome can be applied.