Thanks for the pics - very useful.
So on inspection of what I need to do:
- I need a new arch panel. Looks like the S3 and S2 ones are listed as the same which is handy as I already have a new S3 outer arch
- The shell I have definitely has a very solid fuel filler area - original paint with no signs of corrosion on the outside. Fingers crossed when I cut it off the shell that the inside is good as well.
Now the challenge. The shell is S3 hatchback. The repair is on an S2 SW. The panels to be swapped look the same as long as I cut carefully when I take the rot out of the SW. It looks like I can cut to the sharp corner under the window of the SW, and cut just before the door line, which will help get the panel lined up OK. Just need a decent weld towards the end of the panel (but will be mid panel unfortunately).
I am wondering of I should take the entire SW panel off (spot weld cutter etc) to get the best possible repair on the panel (basically fabricate a new panel out of the 'bits') and then refit it.
Will mean window out, tank off, trim off etc, but looks quite doable.
The filler area is so rusted I reckon I can get the filler neck detached from the wing fairly easily.
The car to repair is an S2 1.7 QV SW by the way. Just in the process of buying it and should be picking it up Saturday morning.
Alfa 75 3.0 v6 Cloverleaf
Alfa 155 Q4 'Winny'
2 x 3.0 24v GTV
Fiat Coupe 20VT
Series 1 Freelander V6