Done a bit of investigation work and it looks like galvanizing will be too expensive and require too much work so hope to visit an industrial paint suppliers this week or next. I have been told about brush on galvanizer and resin marine paints so will price these up as a DIY option.
Did get some more prep work done this evening.
P1140736 by
route9autos.co.uk, on Flickr
With the new panel on the floor I need to accurately transfer the shape of the new panel onto the car as a guide to where I will cut.
For that I need to make up a template.
First job is to cover the panel with tape. The bottom of the 1/4 panel will serve as a line to match with whats on the car and to double check measurements I will measure the door opening down from the gutter line.
P1140737 by
route9autos.co.uk, on Flickr
I then transferred the template onto the car as a cutting guide. I will need to check and re-check measurements before I cut but this will give me a really good idea of where to cut.
P1140738 by
route9autos.co.uk, on Flickr
I will also fit the door after tacking the sill in place before the final weld to check measurements.
P1140739 by
route9autos.co.uk, on Flickr
Unfortunately the new panel wont cover the bad previous repair but I will remove all of the past replacement panel, clean up whats there and make a new plate to fill the space.
I also got the front 1/4 panel and inner arch template in place and as hoped the previous repair line falls within the area that will be cut off.
P1140741 by
route9autos.co.uk, on Flickr
P1140743 by
route9autos.co.uk, on Flickr
Moved onto a template for the front bulkhead;
P1140744 by
route9autos.co.uk, on Flickr
P1140748 by
route9autos.co.uk, on Flickr
With the inner template and the outer template in place the top edges look pretty closely lined up. This will be checked before cutting by drilling a small hole at the top of the outer template and seeing how close it lines up.
I may remove some of the metal from the new panel in this area to make it easier to work with.
Once I sort out the right paint for the new panels I will start cutting.
Dave.