Yesterday I fabricated the flanges that meet with the original rear side window flanges and got them welded in place. Today I started on that big side panel. I first cut a small test panel to confirm the height I needed between the flanges - just about 14 and 7/8 inches and as a pattern at the B pillar. The panel was pretty much the same height as the old side window until it started to curve back to the D pillar. On the lower flange it started to raise up about a foot or so from the D pillars flange. Then it was fit and trim at least 8-10 times to get a tight fit. What’s interesting at the area by the D pillar besides curving horizontally at the bottom, it also curves vertically ever so slightly going to the top flange - it all had to be hand formed! I will get it spot welded after I get another tank of welding gas!
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