Next, we mocked up the new replacement panels using clamps and screws, trimming where required to align the new panels properly, and then cut out the old rusted sheet metal.

Then, lined up the panels for initial tack welding, and then ultimately the finish welding

 

New panels

Picked up a bunch of replacement panels from a local supplier who carries an extensive supply of parts for Minis. He also has quite a few cool Minis of his own, check out his site here.

http://www.mr-grean.com/

Started by test fitting the new replacement panels on the body to get idea of proper gaps required etc.

Then proceeded to bolt up the new (used) replacement doors that we picked up from another Mini builder. Knowing we would be removing the remainder of the entire lower sills, door posts and corner cowl panels, we also tack welded some small tabs around the perimeter of door to allow us to screw the door in place in order to maintain correct panel gaps.

Chop and cut

First order of business was to add some additional bracing on the inside of the shell to ensure it doesn't lose it's shape after cutting out the floor and associated interior bracing.

Then turned my nephew loose with the plasma cutter !

Finally starting

Finally brought the shell into the shop to get started on the body. Shell was lifted up on to our chassis table to allow easy access without having to be bent over all day. The table is quite large and not stored inside so we added some trailer dolly wheels and hitch tongue to allow bringing it in and out easily with the shop service truck.