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.

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.

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.

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.

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.

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.