With steel that thick and wide, does it take a lot of force or hammering to get it shaped round the wooden former? I'd also expect a bit of springback. But then I guess we're not looking at ultra-accuracy here. Some sort of (CNC) flame or plasma cutter would save a lot of time, but cost ££££'s. Or ...

Some more steel cut and inserted. Held on with little magnets until I get the welder warmed up. The grey paint is a special etch primer which can be welded through. You have to remove a bit to strike an arc but it doesn't ignite or contaminate the weld. Had to be done to stop the new steel sheet fro...

CN211276 wrote: ↑Mon Mar 11, 2024 6:50 am I will have to wait until I am back in the UK to open the photos.

You'll probably find them as boring as woodworm. It's just a 26 year old 4x4 getting bodged to within an inch of its life.

What tools have you been using to cut and bend the new metal? Cutting was done with either a metal chop saw with 12" blade or a 115mm angle grinder with 1mm thick cutting discs. If you cut right through in one place as deep as you can and then progress along your marked line it seems to be ver...

What tools have you been using to cut and bend the new metal? Mainly clamps, a vice, hard round bits of anything of the right curvature to bend it over, a bit of steel box section and lastly but not least a big lump hammer :lol: Also made this out of an old gate post. https://i.imgur.com/W0VhLG4.jp...

Next job was to close the gap and join the body to the new wheelarch. Not straight forward due to the curves involved. Decided on 2mm steel for this. Bit overkill but it needs using up. Going to do it in two pieces. Got one of the curves cut and it fits well. Need to cut the top to follow the body. ...

I replaced the sills at both sides 9 years ago. The originals were only made of 1mm steel and rusted from the inside out (as they all do). Initially my hand was forced as somebody ran into the side of me when they tried to overtake and I was turning right. All their fault and they owned up eventuall...

Better shot without the blocks. See how the plastic arch extension is both the cause of problems and hides a multitude of sins at the same time.

All this work I've done so far is largely unseen as it's either underneath or covered by something else. This is the only bit you will see (without the blocks and with the wheel back on).

I can't remember how many hours I've put into this project already. The whole thing is in bits, internally and externally. Underbody rust all wire brushed and treated, fuel tank off and being renovated . All anti roll bars and panhard bar off ready for new poly bushes, old shock absorbers off ready ...