I think you're on the right track but don't take my word for it.
Someone should chime in but I've always thought it better to replace large complex areas as a whole rather than bits and pieces.

The cut line looks good and would be OK but can you go a bit further and separate it at the spot welds?

Thought about doing that but being that this donor shelf is out of an '87, the location & size of the welded overlap area does not match. This is another reason why I'm leaning toward replacing the whole shelf - the stamping is slightly different. I'm afraid if I replace sections, the raised ridges will not line up.

Is there more fiberglass besides the parcel shelf?

Bottom half of the headlight buckets, that I know of. Don't know what I'll find under the rockers.

Post some pics of the issue if you can. So long as the body lines are correct and the flanges mate enough to achieve solidarity the width shouldn't matter. Many of the NOS and repops have incorrect flanges as compared to the factory pieces (most are laughably larger, but some are shorter). I've always operated under the assumption that it is best to replace larger areas when faced with such a choice; that being said, I'm also guilty of welding in a 1" patch (only once, I swear).

Please hurry towards the rockers, I'm in need of some entertainment to keep me occupied this winter . . .

There must have been a discount sale on fiberglass a few years back because we've got a 912 tub with the same issues. Im pretty sure the entire front pan of our car is held together with the stuff, its obscene.

Keep up the good work.

Hey - maybe Colin Chapman tried to Lotusize it!

one could argue perserving the maximum amount of original metal is the way to go.
also replacing entire panels is not always the easy thing. with unibody construction.
patching is fine as long as no rust remains.

I have more fiberglass than metal in a bunch of places on my car as well. fender joining panels were mostly fiberglass. must have been a standard repair procedure at some point.

Didn't get to probe the rockers yet - did attempt to loosen the front A-arm cover bolts and the whole thing just tore off. I saw that one coming. Still drilling out the donor parcel and contemplating whether to replace the whole thing or not. Progress has slowed dramatically due to a little setback - shoulder surgery this week :( It's amazing how traumatic surgery is to one's body, even though it may just be a simple procedure. Check out the new shoulder harness and remote reservoir ;)

http://forums.pelicanparts.com/uploa...1263664493.jpg

http://forums.pelicanparts.com/uploa...1263664949.jpg

Looks like a great start to a homemade Cool-Suit!

Can you bleed brakes with that thing?

sorry to hear about the shoulder - yes, any surgery is heavy-duty -- the body is not designed to be opened up for maintenance...

My mind keeps telling me I need to work on the car, but my body is not cooperating. :( I tried rubbing some dirt on the shoulder but it didn't help any. Not much progress obviously...
I did manage to finally get the donor parcel "comepletely" off. It was a pain in the arse even with it being in a manageable section that I could flip and turn...I'm not sure if I'll be able to replicate the removal of the parcel on the car this clean. Replacing sections (left and right corners) only is quickly becoming more attractive.
I wonder if anyone would be interested in using this as a template to create replacements? (Restoration Design?)

http://forums.pelicanparts.com/uploa...1264393747.jpg

http://forums.pelicanparts.com/uploa...1264393792.jpg

http://forums.pelicanparts.com/uploa...1264393832.jpg

http://forums.pelicanparts.com/uploa...1264393863.jpg

Sorry. Could have shown you this earlier, but I'm not sure of the progress:


http://forums.pelicanparts.com/paint-bodywork-discussion-forum/466913-swb-parcel-shelf-seat-back.html

Gimpy shoulder is healing so no more excuses...
Coming out of my Oxycodine-induced state, I decided to replace just the corners of the parcel shelf in an attempt to retain more of the original sheetmetal and thinking it would be faster to remove less - what was I thinking? After cutting out 10-inches pieces on both sides, I flipped again and decided it would probably be best to stick with the original plan and just replace the whole darn thing.
http://forums.pelicanparts.com/uploa...1266291149.jpg

What was left wasn't looking good...

http://forums.pelicanparts.com/uploa...1266291906.jpg
http://forums.pelicanparts.com/uploa...1266292076.jpg

Aw-heck, cut some more!

http://forums.pelicanparts.com/uploa...1266292873.jpg
http://forums.pelicanparts.com/uploa...1266292216.jpg

I just hope everything lines up correctly - after I'm done welding.

http://forums.pelicanparts.com/uploa...1266292587.jpg
http://forums.pelicanparts.com/uploa...1266292750.jpg
http://forums.pelicanparts.com/uploa...1266292775.jpg
http://forums.pelicanparts.com/uploa...1266292806.jpg
http://forums.pelicanparts.com/uploa...1266292831.jpg

Glad you're on the mend. It's looks like you're making good progress.

Addressed the passenger-side lower rear window area this weekend. Rust in the rain chanel and underside - thought about welding in patches but the same issues of trying to "jigsaw puzzle" the darn thing made me decide to lop-off a bigger section. Wasn't sure if I should cut the rain chanel, but what the hell...

http://forums.pelicanparts.com/uploa...1267417816.jpg
http://forums.pelicanparts.com/uploa...1267417840.jpg

Donor piece massaged in...
http://forums.pelicanparts.com/uploa...1267417931.jpg

...and viola! My first weld. Hot damn.
http://forums.pelicanparts.com/uploa...1267417991.jpg
http://forums.pelicanparts.com/uploa...1267418012.jpg

Not as easy as braze welding, but I'm hoping to improve. At this rate this things not going to be ready until 2012. Will I get a chance to drive it before the world ends?:eek:

Are you using Argon with the Mig Brian?

I am, but the regulator has been giving me troubles, it seems intermittent? Is it that ugly?