[Cammer-6]

Factory used anti flutter in areas such as this.

if youre going to use plastic pick something like this
http://bondo.com/products/fiberglass...iller-274.html

[cfd2bc]

I did exactly what you are talking about doing. I used an expanding foam to fill the void. I used it because the repop piece was very thin and I wanted to make it stronger to block out without oil canning. Also, it seemed like it would dent very easily. As for the seams, I drilled the new panel along the lip and rosette welded it like the factory spot welds. I used dura-glass short strand fiberglass where the panel meets the sail area/ window lip. On the seams, I used body seam sealer. It seams very strong all around. I know it's not factory but it came out looking great.

[6d7gto]

Thanks for the input guys. cfd2bc, did you drill holes in the repro panel then rosette weld the new panel from the inside onto the original sheet metal or did you drill holes in the original metal and weld from the outside onto the repro panel? I'm not sure which way to go since the substructure is in the way at some places (not sure I can get my mig gun in there). Maybe a combination of the 2 techniques? Hope this is clear...hard to explain what I mean to say.

[cfd2bc]

6d7gto, I drilled the new panel and welded from the inside. It is pretty tight, but I was able to weld it all the way.

Jeff