FITTING AN OUTER ARCH

1 Secure the outer arch in position with vice grips, then use an air saw to cut through the top edge of the new arch and the existing arch. Avoid cutting through the inner arch.

2 Cut no more than 2-3 inches at a time, then tack weld the new and old arches together, making sure the panels are butted together. Complete a few tack welds at this stage.

3 After cutting through the arch, the remains of the old outer arch can be pulled out from behind the new arch. If a gap cannot be found to pull the remains through, try carefully levering up the new panel.

4 The new arch can now be butt welded to the existing bodywork. Make sure the two panels are level before welding a section. Complete a series of spot welds to avoid distortion.

5 The raised surface of the weld can be removed using an angle grinder and sanding disc. This will reduce the need for lots of filler to create a smooth finish.

6 The lip of the outer arch needs to be welded to the inner arch. Drill a 6mm hole through the outer arch’s lip, fill it with weld, then sand it flat. Continue around the entire lip.