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Originally Posted by Cloggie
...The worst of it is that rolled over drip rail causes the metal to thin when you grind it all flat as there is a curve as it rolls towards the rail. This then makes a bit bigger gap with a thin wedgelike edge which then exposes the sealer...
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Yep, had that problem too...
Solved it by NOT grinding the gutter completely flush
Leave a little edge (about 0.5mm or so)
It gives you enough "meat" so there's no gap and little blow through and it will melt into your weld puddle very nicely
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Second, the roof and quarter panel do not exactly line up....there is about a 1 to 2 mm drop as the factory did not align the two all that well. It will take lead to smooth it...
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Yep, had that too
Lot of work, but I think it'll pay off. I really like the smooth lines