Rather than crap all over Gydyup's thread, I thought I should start my own. Due to a mishap at the track I needed to replace the RH front fender which was damaged in 3 places:
Since the paint on the car is over 30 years old with some scratches and the normal fading, I decided to give the body a complete winter makeover. First I removed the tranny and motor, then the interior. Finally I removed the windshield, doors and the front cap. Here is an early November shot:
Since I did not know the condition of the cowl vent area, I decided that I needed to start there. I drilled out 167 spot welds and found that the hats were in great shape.
Unfortunately there were other problems that dictated I replace some sheet metal:
I ordered 2 cowl replacement panels from CJ Pony parts:
I then proceeded to cut out the offending metal and trimmed my patches to fit:
You never have enough vice grips for this type of job.
I tacked it into place with my mig welder, then kept going over it until all the holes and seams were plugged. Next I brazed over the welded areas to fill any remaining pinholes that were in the pan area:
After the grinding was done, I needed to strip the rest of the paint with my DA:
I then used body filler to blend the new seams:
Before I could go on, I needed to repair a couple of rust areas on the upper cowl:
I cut out the rust and butt welded scrap metal in place:
Once done to my satisfaction, I stripped the remaining paint off both the bottom and the top of the cowl:


Since the paint on the car is over 30 years old with some scratches and the normal fading, I decided to give the body a complete winter makeover. First I removed the tranny and motor, then the interior. Finally I removed the windshield, doors and the front cap. Here is an early November shot:

Since I did not know the condition of the cowl vent area, I decided that I needed to start there. I drilled out 167 spot welds and found that the hats were in great shape.

Unfortunately there were other problems that dictated I replace some sheet metal:


I ordered 2 cowl replacement panels from CJ Pony parts:


I then proceeded to cut out the offending metal and trimmed my patches to fit:


You never have enough vice grips for this type of job.
I tacked it into place with my mig welder, then kept going over it until all the holes and seams were plugged. Next I brazed over the welded areas to fill any remaining pinholes that were in the pan area:

After the grinding was done, I needed to strip the rest of the paint with my DA:


I then used body filler to blend the new seams:

Before I could go on, I needed to repair a couple of rust areas on the upper cowl:


I cut out the rust and butt welded scrap metal in place:

Once done to my satisfaction, I stripped the remaining paint off both the bottom and the top of the cowl:

