Repairing the front frame.

Today I started withe the repair of the rust in the frame and spring tower on the passenger side.
First I cleaned the part with a wire brush on a grinder.

 Then I started with drilling out the spot welds on the seem of the frame.

 With a cut off wheel I cut out a piece of the frame rail. This gave me access to the top of the frame.

 The rotted pieces were then cut out...

 And new pieces are cut out of a sheet of metal with a thickness of 2 mm. After bending, forming and cutting the pieces to fit I welded all the parts back in place.

 Then all welds are ground flush.

 Then I turned my attention to the front off the frame. On the inside of the engine bay near the front panel I noticed that there were some previous repairs. To be sure they are repaired like they should, I ground of the paint .
It was no surprise that they were not repaired like it should.  

 With a chisel I cut off the the pieces off metal that were tacked in place.  What I found, especially on the driver side I could never have imagined. The chassis was rotted from bottom to top.

 On the drivers side the bottom of the spring tower has been previously been repaired. A piece of metal was bent and tacked in place. After removing it I found one big hole.

 So I removed the front support that I put in place while repairing the floor. This gives me access to the under side off the frame.

 So next I drilled out some spot welds an started with cutting out the frame facing the fender.

Tomorrow I will continue this repair.