I'm looking at my '42 Chevy right now, both front corners on the cab are rotted out, the most serious bit of rust in the whole project. Intending to slice each corner right off with a 4inch grinder fitted with a 1mm thick metal cutting disc and fabricating new inner and outer cowel panels out of a sheet of new stock 1.6mm black sheet metal on the bench.
Lot of curves and stuff down there imnpossible to bend up and shape, will make a pattern and cut each component out of the panel steel and braze them all together to make a single unit and then weld it back on to the bottom of the cab as a complete corner module.
These are outside of the cab floor mounting plate and aren't load bearing, most of the repair will be covered by the trailing lower end of the front fender which attaches to the upper end of the area being rebuilt.
