The plan is to make the repair patches for each of the panels that make up the structure and where possible spot weld the parts back together as per the factory design.
I'm hoping it will all look like solid parts once I'm done - rather than patch here - patch there.
I've shown this approach before - hammer form to get the approximate shape - then use gucci new mushroom stakes to smooth it all out.
Much like the designer dent made for the headlight housing assembly => hash tag free wood rules!
Note I'm not using hard wood - this soft wood junk they make buildings from these days is perfectly OK for my purposes. I've seen beautiful thick steel hammer forms on forums like
MetalMeet - for Metalshaping Enthusiasts & Professional Metalshapers and I could also spend weeks making them too if I was going to go into production - but I'm not - wood is good - it'll end up in the wood burning stove once I'm done and that'll be one bit of crap that won't be cluttering up my workshop.
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Introduction to "Project Binky" - brilliant series on youtube
https://www.youtube.com/watch?v=7hCPODjJO7s
If you have the time it is well worth the watch if you've not seen it already
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Project Binky advocate CAD - cardboard aided design
I do something similar with masking tape given half the chance (cos I too like to keep up with the times)
Because it is already sticky the tape is easily peeled away...
...and then stuck on the surface you want to cut to shape
So as before clamping between two bits of wood and then hammering around the sides forming the designer dent =>
{More in a bit in the next post cos I'm limited to 5 attached photos per post)