Bodywork Repairs page 3
The last bit of welding to do on the Mini is to attack the from scuttle and windscreen surround area. As with most classic Mini’s the area under the screen rubber seal has been attacked by the dreaded tin worm. This area is actually three panels that are spot welded together to make the lip that the screen seal sits on.Once this goes, invariably water will ingress into the car leading to damp carpets and sound deadening, musty smells and then rusty floors, MOT failures, expensive repair costs and Flintstones style views from the drivers seat.
To remove this part of the car I had to cut a section about 30cm long out of the front scuttle. This gave be access to the lip mad of the bulkhead and the top dash rail.
This is the part in question,

Mini’s removed Dash rail and Bulkhead

Transferred to curve to MDF to form the new Mini’s top dash rail section

Clamped new steel between the former’s

Hammered the Mini’s screen lip section over

then marked the line to cut before welding in place to the remaining rail
.