Finished the passenger side A-pillar today. Here's the piece I fabricated next to the cardboard pattern I made to start. Welded the piece in, merging the windshield frame to the door jamb. I am really pleased with the welding improvement after fixing the mig gun. I have been dreading all of these welds unnecessarily. Hundreds of tacks executed today with very few burn-throughs, almost all with good penetration. I am stoked!
Finished nibbling on the three pieces I need to put together to finish the A-pillar. Seven hours of trimming and fitting, fitting and trimming. Finally have the pieces tacked together. All the time I worked on this, I thought about the giant presses GM has to mash pieces like this out of flat sheet metal every second. And GM's fit better, too.
The door skin from the extra Malibu door has a nice curve to the sheet metal that works well for the pieces I need to finish the bottom of the A pillar.
I used the cardboard pattern to cut a couple of pieces from the door skin. A while back I made some small anvils from some pipe elbows. I used one to roll the edge in the side piece; the edge will meet match to the windshield frame. I also used a dolly to form a 90 degree edge that will form the gap with the door edge. I also used the English wheel to crease the portion of the piece that will cover the gap between the windshield frame and the fender.
Capped the open ends of the roll at the top of the firewall. Finished the curved ends for the cowl cover. I am really pleased with the result. I guess a year invested trying to get this right was time well spent.