Ok, this is a biggy.
Work on the shell has been relentless as I want to get it back to SPL asap.
First job was to get him on the rotisserie.........
Now there has been a couple of welded repairs already which were fine for some distant mot of the past but not good enough for this restoration. As we had to repair what was behind them anyway they were cut out and done again. This is before we had touched them......
Also, some areas where two or even three panels joined each other we found that Fiat had been very sparing with the spot welds, and not too accurate with the ones they did choose to put in, it seems they would rather rely on seam sealer to hold the car together. This next pic is looking under the rear wheel arch at the seam where the inner arch meets the floor and chassis rail, often this area rusts badly and when you see it less paint and seam sealer you can see why............
There are very few spot welds here, out of the the ones that made it a couple are right on the very edge.

So as well as cutting out and replacing the rusted areas we also puddle welded some of the panel joints that had more daylight between them than they should.
Although Bucket has a very good shell the areas that did require attention were often hidden behind good panels, the inner sills for example. The only thing for it to do a proper job was to cut out access holes in the good panels, repair the rust, then weld back in the good section. I have so many pics of us doing this that it's probably best to put them all on and let them speak for themselves. They don't necessarily follow in the correct order but I will try to show some form of logical progression................
Interestingly, we also found a couple of tiny stress fractures at the base of both B posts, I guess there must be a few more Pandas out there with this under the paint.
We're nearly there now, just the frenching for the MK4 Panda badges on the C pillars to go.
I did think that with 15x6.5 wheels fitted there would be a need to modify the wheel arches but after trial fitting them on Oslo it turned out that this wasn't necessary. Pics of this very soon, I think you've probably seen enough for one post.
Phew!