The inner fender lip was heavily rusted.

IMG_6963 (1280x853) 

Rusty material was trimmed away and starting to make up the new flange. To make the flange I first drilled the holes using a unibit and trimmed between the holes with body saw. To make the depression for the bolts I sandwiched three pieces of steel,one on the top of the flange and two on the bottom of the flange and tighten them  in a vice.

PEI Summer 2009  (15) (1280x853)

The flange has a slight radius so I used my shrinker die tool to curve the flange.

TR6 039 (2) (1280x853) 

The flange being welded into place.

TR6 040 (2) (1280x853)