OK, time for some more updates. Good news is that pretty much all the ‘not so good’ areas have been found now, so the process of cutting out the rusty, damaged or perforated areas is pretty much completed, so now the bus can get new metal or replacement panels welded back in place!
I’m trying to keep as much of the OG metal as possible, so where a localised area is rusted through, then it is cut back to solid metal and new metal is welded back in place to create an invisible repair.
Unfortunately there were areas that were too far gone and the best route was to use replacement panels, such as the front valence
So far, so good, things are progressing nicely. It is going to be a really 100% solid bus when the metal work is completed.