Just showing how the top box section was bent due to welding in the angled brace. Look closely at the gap on the left side under the ruler.
As the weld cannot be stretched back out I simply use more weld opposite it to pull it back straight again. Done this for many years when welding brackets on to axle tubes etc. I ran two welds on top of each other, letting it cool in between, to pull it straight to add up to the welds that went across underneath as well. I keep the heat straightening welds on the edge only as welding across the box will just create a hollow.
So I have 3mm plate against the firewall spaced out with the same sheet metal thickness as the piece that will fill in this area. Then have the brace supporting the top box section so the outer guard does not take the weight.
This is the template I made for the other side and it fits here too, always a good sign.
From the other side this is the finished fill in piece wrapped around the firewall plate as well is the angled brace.
Also stepped in at the top to line up with the rest of the up turned flange of the guard.
Here it is in place before the inner guard goes back on.
Looks much better having the triangular piece inline with the bonnet edge rather than angled 10mm-3/8" in.
Other side
Now have a nice even gap along the top of the guard right to the firewall as well. I have also been adding a few millimetres of weld along the back bonnet edge in places to even that up some more.
The Jeep
Trailhawk
