When I removed my windshield and trim I found the metal panel badly rusted from water leaking over the years. I cut out the rusted panel but I had to leave about a 1" section along the bottom just under where the windshield is. This 1" section is welded and rusted/fused to the panel under it. My problem is when I test fit the new panel it sits to high because its on top of that 1" section. Do I try to grind that lip off? Cut a 1" pc. off the new panel? Any suggestions? Also it looks like I need to remove my fenders. If I do, will I ever get then to fit correctly again? Are they easy to remove and reinstall? Thanks
Mine was pretty rusty when replaced as well..I added some reinforcing metal underneath the bottom where mine had rotted away..
I'm not sure where your "bump" is, but the windshield glass needs a nice consistent surface to rest on... It can't be really high in one spot. That's probably the most critical aspect of it. I'd try to remove and/or deform it so that you get a nice mounting surface for the new panel. Test fit the glass after tack welding the panel.
The cowl will not really sit on the new upper dash panel, and the fenders should get only close to it in the uppermost corners.. Beware that the corners of the fenders may hit that panel, so if you're too high near the fenders, you may need to reshape some metal a bit.. Test fit your fenders after you tack weld the new panel in.
When you've completed, seal the new panel completely in order to eliminate a re-rust.
Fenders aren't hard to take off.. just a bunch of potentially rusty bolts... I've had no problem realigning them, but some folks say thy've had to jack the nose of the car a bit before attaching fenders...
The way that professionals solve such problems is to hammer the lower metal down until it fits. They like to make it sound technical such as working the metal, but all it consists of is hammering down the metal untill everything fits.
