[njsteve]

Stopped by Home Depot today and replaced the crappy Craftsman Mini Mouse Sander with a Black&Decker model. It worked fine. Using 80 grit, I had all the paint off of the front of the valance in about 2 hours. I can't feel my hands though. Maybe the feeling with come back in a day or two, in time to do the back of the panel.

[njsteve]

Well, here's the finished product. It took a few days of sanding and remelting and reapplying more polyethylene rods but this will work on the car. I left the main mounting holes filled in so I can redrill them in the correct spots one the valance is trial fitted on the car.

[njsteve]

Here are the most difficult repaired areas, the upper mounting points, the turn signal housing and the upper face bar.







The yucky looking yellow stuff in the outer edge of the passenger side turn signal housing is extra welded in polethylene rod I added for reinforcement. It doesn't have to look pretty, it's just there for the added bracing.

[njsteve]

The back side of the panel. I used some fine stainless steel screen and melted/embedded it into the main center fractured area to add some reinforcement. This is the recommended method when repairing areas that will face stress when installed.