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Oh arse! Went digging in into some filler I found on the bonnet seal channel and discovered it’s completely rotten. The O/S might be salvageable if I clean it up a bit more, but the N/S needs chopping out. I’ll make up some repairs in small sections so I don’t loose the shape of the channel. First repair welded in today.

O/S boot now made of solid metal instead of rust and holes.

O/S rear wheel arch repair all welded in tonight. Hoping to get this side all finished up this week.

Finished up the N/S boot repair tonight and chopped out the O/S chassis mount strengthener and boot rot ready to start repairing them.

N/S Boot repair prepped and part welded in today. Pretty toasty in my welding gear in this heat!

N/S chassis mount strengthener removed to see if I could salvage any of the metal underneath. It was all rotten so chopped it all out as well as the edge of the boot panel:

Decided to separate the repair panel so I can get some paint protection between the two panels:

and have welded in the repair panel for the wheel arch:

Pretty much finished up the O/S rear quarter and front arch today before running out of welding wire!

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So chopped out the rotten washer bottle panel and lowered the shell back onto the chassis so I can start replacing the rear chassis mount panels.

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Lots of metal going back into the baja. N/S front arch pretty much done and have made a good start on the N/S rear quarter and O/S front arch.