Metal repairs to the TR4 continue...slowly, but continue. I've got the passenger floor replaced and inner sill on that side. I just finished up repairing the battery tray/firewall area and I'm really happy with how that came out (bought a bead roller...that thing is fun)!
Next, however, is something more tricky, at least for me. The car must have sat for a while and the interior soaked up water and just let it sit on the metal - hence the need for new floors, among other areas. One of those is the top of the dashboard. The cover, referred to as a crash pad, closely follows the shape of the metal and a lot of it on the passenger's side has rotted away in the front. Here's a bunch of pics:
I'd like to repair that area, even though it won't be seen. My initial thought is one long piece, formed to the original as close as possible. But, the rear vertical portion is a concern and, I think more so, the very small flange in the very front (that's maybe 1/8" tall). The vertical rear portion of that channel is in pretty good shape along most of the length, so I'm thinking about starting the repair right at that seam. But, how do I put the small front flange in...or when? Form a long piece of metal, then fold the flange over? Fold the flange along a piece of metal, then form it to match the car? I can go back after it's welded in to fix the portions of the rear vertical area.
I know I've got some shrinking and stretching to do in here and the very small flange probably adds difficulty. I consider it a challenge that I'd like to tackled, but I don't want to waste a whole bunch of metal doing it. Any advice anyone is willing to provide on an approach is much appreciated!
Thanks,
Chris