On top of that, I was able to cut out the bad portions of the rear passenger wheel housing lip and weld in patches I cut from the larger Klokkerholm patch panel. It still needs a little bit of filler to even it out, but it's solid and actually looks pretty decent for what it is. I still need to weld it closed inside the trunk.
But, the passenger side of the car is nearly done. I still need to make a patch inside the wheel well and rebuild the passenger side hood spring perch. But, the floor and rocker are solid again (though they still need finishing - paint and truck bedliner).
Now that spring is here, I'm hoping to be able to work on the car most evenings when I get home from the office, which should help speed the project along. My goal is to be driving it this summer.
rusted wheel well lip and formed repair panel
rusted area cut from rear of wheel well lip
checking fit of the repair patch
patch piece, clamped in place for butt welding
patch tack welded in place
welds ground down
front of wheel well lip - spray paint is from previous owner
crud and dirt caught inside the panel - needed to clean it out
patch welded in place
repaired wheel well lip - still needs a small bit of filler to smooth it out
patches inside the car, seam sealed - still needs final coating