Rare panel remade

1 New metal required

Look at the main pic and you’ll see the problem. Early valances are unobtainable, so there is only one thing for it. Measure and cut out.

2 Template time

The ridged strengthening panel is the tough part of the job. Measured up and new metal marked.

3 Clever bit

With holes cut lay the new metal out on some scrap wood, gouge out the wood to match the profile required and hammer it into the voids.

4 Cut and create

Hold the new panel up to make sure that everything is correct. Cut out old and weld in new. Tack it and use short runs to avoid warpage.

5 Time for the dressing

With the strengthening panel in and painted, measure the gap to be filled and cut new metal to size. Offer it up repeatedly to get the fit just right along the top edge.

6 Weld & grind

Painstakingly work the panel as you weld it. Cut and hammer until it is in place. Grind, then fill.