Moving on, the door base is sound front and back and the top is next, I sliced off all the scraggy bits with the angle grinder but the top was too rusty to save so after some careful measurement recording I made some brave cuts. The inner and outer panels cut a couple of inches apart to aid a good graft. Note the prepared replacement strip resting on the bottom of the window arperture, this in 2 parts (see sketch in window). This has an inner part (Black) outer (Red) crimped to the upstand and tack welded in a few place (Blue arrow). The new bit was crafted on my high tech!! bending machine: This is basically 2 stout steel tubes with the panel to be bent (Grey) and a former (red arrow) sandwiched between and gripped by vice and clamps. The former is a steel bar with the edge ground to give the correct radius. The flange is bent with many passes of a steel bar and lump hammer, crude but effective. New top fitted with 4 plug welds some seam welds and now ground back and Bonda'ed. The outer flange is deliberately a bit long to add strength in storage and allow more careful trimming to final size when I have the rubbers and glass ready. I have also fitted closing pieces to the window sides which will be covered with the original GRP bits and carpet/vinyl. Time for a holiday from sheet metal work as my next task is rear hubs/bearings/CVs. But I have some nice bits en-route from Cool Air so will be skinning a cab door later.