Sorting out the rust lip for the door rubber

Moving further up the door pillar I started by cutting out rust from the joint where the door seal goes onto. This took some grinding and sanding to get all of the rust off.

Fortunately only the one side was rusted, with the inner part being ok.

I cut a length to replace the part and drilled a number of holes in it, before welding it all up and grinding the welds down and clean.

Next it time to tackle one of the more difficult parts, the hole rested out below the windshield where a whole bunch of pressed panels all come together. I started on getting the shape using some masking tape to cover up the missing metal.

My thinking was to use this a guide to shape the metal.