bluecab wrote:Does it involve roofing tar or JB weld?
No, really. what did you come up with?
David
lol, roofing tar! Of course! Why didn't I think of that?!?
Naw, I finally got off my lazy butt, (And it got to be a respectable temperature outside) so I went ahead and tried the longshot of making a template, and seeing if the part could be made with flat metal... Good News! It can

I made a piece out of some fiberglass panel I had for testing purposes, and it fits quite nicely. All I need to do is replicate it in metal.
Now I do have 2 questions though:
What kind of metal should I use? I was eyeing some galvenized roof flashing, both for it's rust-resistance, and ease of transport.
Is welding the best choice? If I go to weld it, I'll have to pull pretty much everything flamable infront of my seats out, dash, electronics, duct work, etc. And cover all the wiring.... I understand there's a new adhesive they use for attatching body panels now a'days, I was wondering if i couldn't just cut out the worst of the rot, POR-15 everything in reach, and "glue" the new piece ontop of the old.
Here's some pics of the fiberglass mock-up, btw



