Hi Gerry,

I don't have many more photo's, but I'll try to explain the process. First get the fenders off...rusted bolts etc. make this fun. Then I used my reciprocating saw (sawsall) to cut along the inner fender arch and up along the footwell. Then cut off the radiator support section and separate the top section with a grinder with a fine cut-off wheel. The replacement panel is designed to fit under the existing fender.

I punched a series of 3/16" holes along the edge of the inner fender so that I could button weld then panel in place. For the test fit, you have to tack weld the top and bottom of the panel in place...don't worry if the bottom of the panel does not align with the existing fender just yet. There isn't that much adjustment in the fender, so this is the part that takes time. Trial fit the fender and check the hood and door gaps, you can adjust things by moving inner fender prior to welding. Then weld the firewall flange and recheck the fender gaps. I then welded the corner where the firewall intersects the wheel well (at the base of the angle part of the panel) and recheck fitment of the fender. This takes a little effort (a second set of hands would have been helpful).

Next button weld the holes that you punched, making sure that the replacement panel is in contact with the upper by hammering it up as you go. Once I welded this in place I coated it inside and out with POR-15 rust treatment (I had coated the inside of the box section prior to welding and after I added the studs to the inside). I gave it two coats, that should do the trick. Tonight I will apply a polyurethane seam sealer and then under coat the inside of the fender and inner parts prior to reassembly. This should keep the rust at bay.

Hope this helps.
Craig