#fordcortina

With everything having a generous, dry coat of paint, I put seam sealer along all the edges that needed it, similar to how the factory had it. I also cut out the rust on the door frame just under the scuttle,

With the rust cut out and surrounding metal treated, I got to work welding in ptches of metal. I learnt my lesson on the previous side, where I had tried to create one large piece and weld it in in one

Spurred on by the feeling of accomplishment of finishing up the left hand side door frame I moved to the right hand side, starting with the scuttle. From the outset I could tell there would be more rust,

With the scuttle welded back in place I could proceed with closing up all the last of the places where I had cut rust out around the door frame. First a piece was cut to shape and bent to close up just

After quite a long time, my last post was in May, I got to closing up the scuttle panel in December of 2024. I made use of plastic tile levellers to hold the piece I had cut out ages ago in place. While

My hair brained scheme to route whatever water leaks behind the windscreen rubber out may work, or not, time will tell. I am definitely not ready to solder plumbing connections but this works ok enough.

After much back and forth, test fitting and finally some paint, the bottom has a decent coat on, I managed to get something welded in place. I still had to tweak the part a bit so that the part of the

I had some small details to finish before welding in the patch under the windscreen cowl. There was a tiny hole to patch and I marked the places where the holes should go to spot weld the part on to the

As is probably expected the part I cut out warped a bit and does not fit back in position perfectly. I picked up some of these, they are meant for leveling tiles, i figure that, if I don't weld too close

With the rough shape I started refining it until finally I could get the piece I cut out to fit over it. It took quite a bit of back and forth, offering the two pieces up, cutting, then bending, repeated

I pondered a long on time on how to get started with this piece. Eventually I just took the bits I had cut out and used them as a guide and cut a section of plate to match, a bit oversized. I then bent

Not an lot of change visually but I did spent quite some time welding in thin strips to replace the rusted edges that I had cut off / back to get to clean metal. This is just to restore the length in

Cutting out rust from the inner layer meant I could now see through and into the cab... I chased down the last bit of rust into the engine bay as well and made up a tiny sliver of a patch and welded it

I tried cutting away the least amount of metal, so that replacing it would be somewhat simple, unfortunately I found more rust after I cut the first piece out, so I cut some more out, until it was only

It took a while but I finally managed to gather up the courage to cut a large hole in what, on the surface, looks to be good steel. It's actually not as bad as I expected but I will still have to cut out

It was quite obvious that there was rust on the edge of the windshield, so I cut out a small section to see what I might have to deal with. After a lot of procrastination I cut a small plate of steel and

The more I scratch the more rust I find, there is nothing to do but to cut it out. This time it is right at the top of the drivers side door pillar by the upper door hinge mounting. I cut out as small

Using the template made from masking tape before, I cut out a piece of metal plat and tried to figure out how to get it to fit the shape, it's not obvious from the photos but there are quite a few curves

Moving further up the door pillar I started by cutting out rust from the joint where the door seal goes onto. This took some grinding and sanding to get all of the rust off. Fortunately only the one side

Even though I did not get much. done, the curve piece I welded in is the last part to go on to the outer sill before I try and coat the inside from back to front in paint, still figuring out exactly how