For those of you wondering what happened, why no updates. My AC went out Friday night, 5 minutes later I discovered a 50 amp contactor melted. The type of part you can't buy on a weekend, especially a holiday weekend. It got too hot for me to do much, so not a lot got done during the long weekend.
These pictures span about a week.
Epoxy Primer should keep the inside rust free.
I primed the edge where the skin folds over the inner bracing.
A couple of shots of the lid installed on the car.
What's left. I have 3/16" of shims on the right side. I think I need 5/32" of shims for better alignment. No shims were needed on the left side. This was because the hinge support had busted loose and I moved it higher before welding it back.
Things remaining on the rust repair/installation.
1. Fabricate a 5/32" shim.
2. Tack weld the skin to the inner bracing.
3. I still need to tweak the lid slightly for better alignment.
What did I learn and what would I do different next time.
1. I would make the patch in three pieces instead of two. I think I could have better handled the distortion caused by folding the edge over.
2. I should have pulled out my TIG welder for this job. While the patch was perfect before welding, the long seam has some distortion/warping. This really is not a big issue, since I need filler anyway to take care of the collision damage. While you can seen the seam in the picture, the amount of distortion is no more than the thickness of card stock.