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Lotus bonnet front edge reconstruction

As part of the reconstruction of the Sunbeam Lotus, this section is devoted to the refabrication of the front edge of the bonnet, which had virtually disintegrated.

The edge from the underside. Both the inner shell and the outer skin need replacing along the edge, as can be seen.

Starting with the inner shell, a strip is cut off the edge, back into good metal, and a new strip is made identical to this. It is being done in sections so as to ensure that the new is put in, in exactly the same location and at the same angle as that which came out.

All tacked into position.

Then the next section is done likewise.

All seamed up using the overlapping tack welds technique to avoid distortion.

Welds after grinding back. Inner shell now repaired.

Now the outside skin, and as can be seen, the edge is in a mess, having been covered up with filler for quite a while. It is generally in holes for the whole length.

Below can be seen the cut off edge, with the cut out piece on the bonnet behind it, a new strip just cut from the sheet to form the new edge, and a profile gauge to check the shape.

Here we can see the finished new strip, with the turn over, next to the old one, and all sprayed with cold galv spray, as has the inside of the bonnet skin, just replaced.

Now clamped into position either end, the new edge stays where it is needed without further persuasion. Tack welding beginning.

Whole length now seamed with overlapping tacks. Offering the grille up to ensure alignment is okay. It is.

The seam after grinding back, ready for lead loading.

During lead loading.

After lead loading and skimming with filler and stopper to obtain perfect profile.

After ten rollered coats of two pack primer, and guide coat applied, ready for final profiling with long sanding block and 180 grit paper.

After profiling the two pack primer, six coats of cellulose primer are sprayed on, and again guide coated, ready for final rubbing down with 600 grade wet paper before the colour is applied.