And this? Guess what? They don’t look like that anymore. Want to know why? Of course you do. Those areas don’t look like that anymore because some poor fool spent a lot of time watching football and fabricating parts and welding them together. (What can I say? The playoffs came on when I was in the middle of it so I moved the fabrication operation into the family room and cut metal while I watched football. And what could possibly be more manly that that? Except maybe giving a wild baboon a beat-down with a pipe wrench during the commercials.)
Next I spent a lot of time making cardboard templates and fabricating this little piece (as the Denver defense gave the game away). It allows air from the cowl into the vent and keeps the water out of the vent. It was somewhat challenging and kind of fun on some sort of level.
Here is another view of it clamped into place. I used 3M panel bond on the inside far edge and welded it on the outside edges. (No, it is not duct taped in place. The tape was to prevent the cutting of flesh each time I had to reach my arm up in there. But yes, I put it on there after some cutting of the flesh.)
Then it was time to weld up the outer pieces but before we get into that I forgot to show you the window frame repair (it was actually done first.)
There were a couple of pieces that had to be welded around the bottom of the window frame. Yes, I know it’s ugly. It was a pain as they were odd shapes and difficult to fabricate with my crude tools. I suppose it’s a good thing they wont be visible again until the next poor fool takes it all apart to restore it thirty years from now. Anyway, let’s get back to the rest of it.
Then I made a piece for the side and welded it in place. Of coarse there were a few other little pieces that had to be welded here and there but I’ll spare you the details. After everything was welded up it was just a matter of sealing all the seams with panel bond and doing a little filler work on the window frame.