The new engine lid I bought for the van is for the later pin style hinge, and as I wanted to keep the earlier proper hinge I needed to convert the mounts.

The first step is to cut off the pin hinge and weld shut the hole:

Then cut the slots for the hinge:

I was originally going to fit rivnuts but I wanted adjustable nuts, and rivnuts would sit slightly proud of the surface so I had a cunning plan.

Firstly drill holes for where the nuts will sit, but additionally drill a secondary small hole next to it:

Then in an attempt to replicate a cage nut, fabricate a u shaped bracket with a tab to weld to which fits the nut with a small amount of wiggle room (I welded blobs to the corners of the nut too):

Then using a pair of allen keys coax the nut and bracket into position behind the holes and hold in place with a cleco clip (unbelievably faffy and very nearly resulted in me throwing the engine lid across the workshop):

Followed by a confident plug weld through the hole to hold it all in place. 

Repeat on the other 3 nuts and the job is done. The lid fits pretty much perfectly now:

And shuts with a satisfying thunk:

Today saw the new rear outer valance going on the van.

New valance all prepped:

and inner valance prepped too (note the small tabs welded either end for the returns on the outer valance to fold around):

Lots of clamps:

And all welded in. An easy panel to fit for once! I just need to dress the welds and fold the returns around either end.

Fitted the rear arch and started welding it in. Looking good!