The second and more complex part in terms of both shape and condition is the rear lip. It's damaged by about 70%. The donor had a better remaining shape but was almost entirely corroded through on its surface at several spots. This part is complex, measuring 140cm in length with a cross-section of 20 cm and being quite curved along both dimensions. The possibility of it working as a knee support is very slim, finding a living donor remains within the realm of fantasy due to similar problems among donors indicating this is an inherent issue of this model, embedded during design or production stages. Therefore, out of available options, either manufacturing dies to stamp and sell them at around 50 thousand per piece or restoring the existing set with holes is left.
I started by cross-matching both metal pieces along a complex trajectory that allowed for shape restoration and removal of some holes. A hybrid resulted but still had an alarming number of corroded areas, so I had to add foreign metal again.
A small lyrical digression.
Regarding the use of foreign metal, this was said in haste. In selecting the metal, I approached it more logically. I decided to use bodywork metal from rejected body parts, with Nissan Terrano 93, Mazda Bongo 92, Toyota Hiace 85 being among available options fitting by thickness. All good about Nissan but they rust too much, leaving Mazda and Toyota, further logic suggested choosing Toyota due to chemical composition considering the manufacturer and proximity in production year reducing mismatch or electrochemical couple probability. Thus, a large piece of Toyota Hiace's right rear door from 1985 was grafted onto this project as donor.
And then
marker ruler sheet
grinder vice hammer
hands eyes patience
welding and a bit of skill
Result, the part is assembled from 14 separate sections, with 60% new metal, 40% salvaged from existing two parts. All corrosion removed, seams treated, sandblasting and chemical treatment remain to prevent welding joints from rusting, along with assembly and painting.
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