1980 Austin Princess mild custom - 1951 Lanchester LD10

Right, I'm taking tomorrow off. I'm knackered. Let's see what I got up to today, shall we? That bleb on the passenger sill was explored, it wasn't actually much of anything, just a scruffy weld presumably to bridge a little hole.
20170722-01 by Angyl Roper, on Flickr

It's what was underneath that was the problem. Fortunately, I've got a big enough section of outer sill to sort this out. Eventually, it wants a full outer sill fitting this side, I'll save that for when/if I buy new front wings in the future.
20170722-02 by Angyl Roper, on Flickr

To offset that unexpected find, I cleaned back and inspected the boot repair and found that it was, overall, not too bad. There wasn't really anything to gain by cutting it all out and doing it again so I flattened off the welds and applied some more welding where required. Then flattened everything off again, gave it a good dose of seam sealer (which I'll do on the other side too, which incidentally has some welds of serviceable quality too), primed and painted. This did take rather longer than I made that sound, especially since it's not the most comfortable bit of car to be working on. Didn't have any Harvest Gold so for now it's just black, I'll go over the interior of the boot with green to match the cabin once I've done all the repair work back here.
20170722-03 by Angyl Roper, on Flickr

Chased out some pinholes I'd noticed on the headlamp repair section before flatting that back ready for a little bit of filler and paint. Also found the missing part of the donor wing for this side, a piece I'd previously dismissed as random scrap, so that saved a lot of time on the lower wing repair. Used some fresh steel to bridge the gap where both donor and original wing had rotted out.
20170722-04 by Angyl Roper, on Flickr

20170722-05 by Angyl Roper, on Flickr

Repaired a couple of smaller holes on the original wing where it meets the corner section at the front and I've still got a couple to do underneath which I'll find easier when the car is up on the lift. For now, those areas that were ready got some filler and then everything got a dose of primer partly to tidy things up, partly because the car may have to go outside next week at short notice and I don't want it sitting outside in bare metal (I know primer isn't much better, but it's better than nothing). It needs work on the filler to be ready for paint but is very close now
20170722-06 by Angyl Roper, on Flickr

The other boot corner that I need to do work on isn't too terrible. I was tempted to do it today but I ran out of steam when I realised how fiddly and time-consuming some of it is going to be to put right. With the exception of the driver's front corner, the welding that remains really needs the car to be on the lift to sort out. I'm not especially looking forward to replacing the front floor pan, but needs must.

Finally, can anyone identify these? They don't seem to naturally fit anywhere and while they look similar to the engine/ignition cover, they don't seem right for that application. They also seem to be handed but are nothing to do with boot interior trim or inner wing guards so far as I can work out, which is where I would have expected this sort of shaped thing to go. It has been suggested they're ignition shields for a Mini.
20170722-07 by Angyl Roper, on Flickr

Couple of people now have confirmed they're for Mini and they're the ignition shield. A slightly different design to the standard ADO16 one in that there's a cut-out for the dipstick so I can fit these to my car which would look nicer than the taped up original.

Yeah but... Harvest Gold D: Limeflower I'm okay with, but not Harvest Gold, it's a dreadful colour and not in a good way.

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It's been a day or two since the last update, I bet you're wondering where I got to. Never fear, a new update is here. Yesterday I went in with some goodies that had arrived but couldn't do anything as the unit needed to be a clean space for the day, so there was no way I could be doing grinding and welding. That's okay, I got a bit ahead on some work projects instead and left the new parts for today.
20170725-01 by Angyl Roper, on Flickr

Mike was going to be in the unit ahead of me today and offered to fit the clutch slave cylinder and repair the wiring loom. I wasn't sure if he'd have time and they're non-vital items at the moment so I didn't mind if today was just me cracking on with bodywork. Happily, there was a note.
20170725-02 by Angyl Roper, on Flickr

Well, that was nice. Old slave cylinder well and truly jammed, the pedal actually moves properly now. It needs to be bled to work fully, that's a job for tomorrow, hopefully. Wiring loom was all repaired and wrapped to Mike's usual high standard so that's another worry out of the way.
20170725-03 by Angyl Roper, on Flickr

20170725-04 by Angyl Roper, on Flickr

20170725-05 by Angyl Roper, on Flickr

I had spent some time yesterday looking at the car and the inner wing panel and imagining how to fix it. This is a much more involved and scary repair than I've done before as it's all peculiar shapes and I pretty much had to do it with the panel I'd got, there's no spare funds for another at the moment. It was a case of offering the panel up, marking and trimming it about a thousand times, then doing it a bit more, and a bit more, until I was as happy as I could be. I did have to remove more inner wing than expected at the front because of rust but much less depth of wing.
20170725-06 by Angyl Roper, on Flickr

Clean it up, tack it in, bash a few edges for a slightly better fit and massage bendy bits of panel so they line up as good as possible and it's starting to look something like. Oh, and clean off the surface rust too, of course.
20170725-07 by Angyl Roper, on Flickr

Eventually, the whole repair section is seam welded and plug welded where required. I went over the middle subframe mounting plate again and got the welds more even and hefty to improve that area. There's one corner of the subframe mount I can't finish until I've done some rust repair, but I needed the upper section of wing in before I could do that, so that job happens later this week. I was quite picky about both sides of the welding, part of the reason for doing it from the inner wing side is the ugly side of the welding would be less visible. Once I was happy that everything was properly seam welded with good penetration and a reasonable finish both sides I treated it all to seam sealer, primer and paint. Where you see the flashes of grey primer is where there's rust repairs to complete
20170725-08 by Angyl Roper, on Flickr

I decided against fitting the trumpet to the inner wing panel before fitting the inner wing panel for two reasons. The first is that the spotweld holes I need to access are accessible with the panel fitted, something I didn't know until it was ready to be welded in. The other is that the trumpet is a terrible fit. I've been trying to squash and bend and straighten and tweak it and it's something like but it's going to need clamping to the wing and bashing into place to get it to sit right in some areas. I don't know if the fitment issue is down to the inner wing panel or the trumpet, both or the car, it's just one of those things. It was one of the parts of this repair that was worrying me what with there being a lot of complicated shapes having to slot together neatly.

Never mind. I got the engine bay side of the wing seam sealered as tidily as I could. It should be a much less visible repair once the battery and wiring are reinstated and it has some paint on. It's all metal now, at least, and will hopefully take at least another 45 years to rot out again, by which point I don't think I'll care.
20170725-09 by Angyl Roper, on Flickr

20170725-10 by Angyl Roper, on Flickr

I am looking forward to getting this engine bay tidied up. There's a small piece I need to put in between the bulkhead and the inner wing where it was cut away for the repair before I got the car, a fiddly job but an easy one at least. I wanted to do this after the inner wing was fitted so I could make the repair the correct shape easier. I didn't cut through any wires or set anything on fire today, which was very surprising, though I did make the obligatory blood sacrifice by accidentally stabbing myself in the hand on a drilled hole edge.
20170725-11 by Angyl Roper, on Flickr

I considered doing it that way, I just wasn't keen on cutting out any more than I had to.

Consider it a new thing learned, which is something I'm still doing with this sort of work

I am in envy and awe of your skills and progression here.

The progress is looking good   

When you have the headlights out it's an ideal time to do your best to protect the wings around the headlight bowls.
At a minimum, I like to coat everything with some rustproofing ( I normally use wax based )
Or make some splash shields to go under the wings, to stop the mud and road spray from getting up behhind the headlights.

Looking great

I remember cutting through a wiring loom on a customers car years ago when I worked for Charlie Browns, felt like a right donut because the customer was watching at the time.
Took ages to repair

Great progress! I'm by no means an expert, but I have some further tips from experience that you may or may not find useful. Also, if you haven't done so, read the Making Panels thread (again)!

I'm a big fan of wrapping delicate stuff like looms and glass in fire blankets when grinding and welding, 1x1m ones are as cheap as 4 quid apiece and I find I never need more than two or three at once to cover everything that needs protection.

Do you have a power file? If not, get one, they're great. I've never used one, but I'd say even a cheapy from Aldi or Lidl will do the job (I have a 25 year old Black & Decker).

It would probably have been easier to bolt it on with a few M5 or M6 bolts first and position it bit by bit. Just drill some though holes and weld them up when the panel is welded on. Alternatively, lightly tack weld the panel in position in a few places, you can always cut the welds (one by one) to reposition. Make sure that if you move something, not everything else moves with it, panels can be like waterbeds if you try and clamp them like you did.