My hair brained scheme to route whatever water leaks behind the windscreen rubber out may work, or not, time will tell.I am definitely not ready to solder plumbing connections but this works ok enough.I welded up the original cut that I made then ground that beck and gave everything a decent coat of provonite. This will take a day or two to cure fully, then I will seal up the remaining gaps with seam sealer as was done by the factory.#cortina #rustrepair #fordcortina #cortinabakkie #fordp100 #restoration #cortinaldv

After much back and forth, test fitting and finally some paint, the bottom has a decent coat on, I managed to get something welded in place.I still had to tweak the part a bit so that the part of the cowl I had cut out does not contact the door, seems that no matter how hard I tried when test fitting the part always moved a bit. I have been taking these small issues on, one by one.There is still a bit more fiddling to be done before I can weld the top part back.#cortina #rustrepair #fordcortina #cortinabakkie #fordp100 #restoration #cortinaldv

I had some small details to finish before welding in the patch under the windscreen cowl. There was a tiny hole to patch and I marked the places where the holes should go to spot weld the part on to the body.As I have been doing this I have been test fitting the part I cout out and making sure the door closes without touching etc.#cortina #rustrepair #fordcortina #cortinabakkie #fordp100 #restoration #cortinaldv

As is probably expected the part I cut out warped a bit and does not fit back in position perfectly. I picked up some of these, they are meant for leveling tiles, i figure that, if I don't weld too close to them, I might be able to use these to hold the part in place.Generally the fitment is ok, I had quite a bit of back and forth to get it as close as I can.#cortina #rustrepair #fordcortina #cortinabakkie #fordp100 #restoration #cortinaldv

With the rough shape I started refining it until finally I could get the piece I cut out to fit over it.It took quite a bit of back and forth, offering the two pieces up, cutting, then bending, repeated over and over until they fit well enough to go back on the cowl.There is still much to do before the two part align well enough to weld together but before I can think of doing that I want to get the door back on and make sure that everything will line up.#cortina #rustrepair #fordcortina #cortinabakkie #fordp100 #restoration #cortinaldv

I pondered a long on time on how to get started with this piece. Eventually I just took the bits I had cut out and used them as a guide and cut a section of plate to match, a bit oversized.I then bent and trimmed and trimmed and bent the plate until I could get it wedged into the space.Using the original part and the paper template I had made I traced the outline of the curve and used a small hammer to bend over the edge on my vise and a small 5kg anvil I bought years ago.I tried rolling the metal over the bottom of the windscreen pillar but I could not get it to match the shape very well.Still rough but it looks like it may work.#cortina #rustrepair #fordcortina #cortinabakkie #fordp100 #restoration #cortinaldv