I've been playing at the Votech class and doing more cutting and welding. It's quite amazing what you can get done in three hours when you have a dropdead time to move it out of the shop and head home when the class is over. I spent one class cutting and trimming the bad section of the upper drop-off that mated up with the outer wheelhouse on the passenger's side. The seam between the two panels was soft so I elected to cut the seam out so I had an easier area to weld from (inside the trunk), instead of trying to recreate the mated area underneath the car which is blocked by the frame rail.
Here's the before shot:
And after trimming:
I used the upper portion of the drop off and an extra leftover section of flange and welded them together to pre-form the mated seam between the trunkfloor and the drop off:
And here is how the replacement piece fits:
