I bought a few sheets of metal ready to make the outer cowl panels, and on Saturday I drew the template onto one and cut it out roughly with the air nibbler. After a bit more shaping with the grinder I folded it on the garage wall corner as that was the only straight edge I could find that was big enough. The rest of the edges I folded and hammered in the vice and test fitted the panel. After a few adjustments, I decided that the patch I had made a good while back had to go, so I ground it off and cut a new one that would fit better. The result was much better, though ultimately no one will see it as it sits under the cowl panel. Once it was done the panel sat a lot better than before and I re-trimmed it to fit.

When I was happy that it would fit, I trimmed the rough edges of the cowl and the new panel to suit. I made sure all the edges were clean to weld, then painted the inside with ratlle can primer to give it some protection. While it was drying I hammered out the welding I did last week where it was a little lumpy. Once that was done, I tacked on the panel, made a few adjustments, then worked my way round till it was all on. A few more small panels were needed to smooth the joins over, and the gaps were filled with weld. After a while with the grinder it was smooth enough to sand ready to fill. Now I just need to do it all again for the other side.