my new integrale

[Kevinlincs]

As the replacement panel had been handily removed with more material than I really needed I could make the decision to join it to the bulkhead inside the car behind the dash rather than the windscreen flange itself.
The A pillars I planned to stagger the joins rather than just jut straight through the whole pillar as that's not a very strong way to join it. The outer panel would be cut about half way up, the door section corner kept all original and the inner pillar would be cut a few inches from the bottom.

[Kevinlincs]

Measure, measure then measure again before cutting a big section of car away at this late stage!

[Kevinlincs]

Passenger side not too bad, clean up about all that was required..

[Kevinlincs]

Drivers side not so, but nothing too bad

[Kevinlincs]

Well worth removing the original panel though, far worse underneath than even appeared on top!

[Kevinlincs]

Repairs made to the box section underneath then a new top laid on

[Kevinlincs]

As you can see from this the "new" panel was in very good shape but even it had some rust around the little drain tubes from the 'screen corners

Note too how much has been remove from the donor panel, always best to use as little as you need

[Kevinlincs]

My own opinion on those drain tubes is they create far more problems than they solve, every car I've now done that has had them has had issues around them, be that the AlfaSuds or anything else.
So I cut the rot out, made up new sections and have welded them over.

[Kevinlincs]

Using the alignment frame to check things...

[Kevinlincs]

And using the body panels to check for bonnet and wing alignment...

[Kevinlincs]

Let the welding begin!

[Kevinlincs]

Plug welded to the bulkhead and overlapped on the inner A pillar, careful not to leave sharp edges for the sunroof drain tubes!

[Kevinlincs]

Repairs to the drivers side bulkhead..

[Kevinlincs]

Grinding off takes an age 

[Kevinlincs]

Worth the effort though, outer pillar joint came out well both sides.