Sorry wanted to give you a link to the dutch 2cv forum, a member over there just did the same thing with lots of pics, but I can"t find it.... When I find it I post it here as soon as possible..,.

Makes it easier if the engine and box are out of it and the rack isn't bolted down. You have good access and can occasionally refit the rack to make sure the hole is lined up right. If you don't have to remove the floors and A pillars you're onto winner with lining the new panels up. Aside from that, drill out the spotwelds then remove the old panel, clean up the mating faces (the upper bulkhead where you weld the lower bit on is pretty thin and you will probably blow holes in it), drill new holes to spot weld through (or use a spot welder to do it properly) and stick the new panels in. Spot welder is the nicest way to fit A panels if you've got one. Never seen one look the same as original if done with a MIG.

Yes I found the link....http://forum.2cv.nl/viewtopic.php?t=8081&start=90&postdays=0&postorder=asc&highlight=

starting at about the middle of this page.... I think this is what you need.....

That's inspiring! Thanks very much.

Finally got some time to work on the van yesterday.

After my slough of despond concerning the bulkhead last month, I went back and had another look. It wasn't as bad as I'd feared. In fact, it's really good, apart from a section around where the pedals go.

So I got busy with the impact wrench and angle grinder, and cut out the rot:






Then I carefully welded new bits in place. Setting the Portamig to lowest setting really works well on thin A-series metal.

Forgot to take pics of the end result... I'll bag some later in the week.

Also started cleaning up the surface rust on the inside of the van and sealing the cleaned up bits. Felt like I made good progress. Light evenings really make a difference!

Whilst I'm full of admiration as you're clearly more fired up about fixing your 2cv than I am mine, but I think you'd be happier with your results if you bought a few abrasive flap wheels/soft pads/sanding pads (different people use different terms) and ground the welds back the welds to smooth it off.

I agree, it looks so much better and it gives you more satisfaction.

You're absolutely right, and I will be investing in those items in the next few days. However, like a kid in a sweet shop I wanted to try out the brushing paint that I bought last weekend! Totally arse about face, I know, but I just couldn't resist the satisfaction of painting. Also gave me a great opportunity to make little lights flash in my head off the fumes.

Another thing: for the first time ever it gave me the peace of mind of sealing the metal, rather than leaving it for months to fester before I have to spend hours making it good and rust free prior to painting.

Never been very good at strategic planning, me.

I shouldn't have been so righteous, I just did an mot patch on my mx5 and it looks fucking dreadful. Could I be arsed tidying it up? No. No I couldn't.