 24 Rather than trying to...  24 Rather than trying to cut out the angled pieces of metal exactly as the pattern, we made the pattern straight for ease of layout and cutting. The design was drawn out on the steel and then cut. |  25 After adding a small cut...  25 After adding a small cut at the bend location, (which allows the piece to be bent to match the original window opening pattern), the new replacement piece was bent around a bar and carefully hammered into shape. The separation shown in the center-where the cut was made-made the curved center point a little simpler to fabricate. |  26 our new piece was fitted...  26 our new piece was fitted inside the channel; they overlap on top of the corner we installed previously. |
 27 The longer piece was tack-welded...  27 The longer piece was tack-welded to the channel edge, tucking under the top piece so that it can be smoothed down. a body hammer was used to make the transition into the corner exactly fit the lower structure we added earlier. |  28 Next, yellow cardstock...  28 Next, yellow cardstock was laid into the window channel and a pattern was marked. the inner edge was trimmed and made to fit. |  29 This is a flat replacement...  29 This is a flat replacement piece cut out of sheetmetal and has holes in it to weld it to the channel. It was fit, clamped in place, and the initial tack welds were done to hold it in place. |
 30 Clamped down again, we...  30 Clamped down again, we began final welds on everything. |  31 Be careful and take your...  31 Be careful and take your time welding. Hit the area once, move to another area, hit it, and go to a third area. Never add more than 1/2-inch length of weld to any one spot at one time. |  32 With the edges welded...  32 With the edges welded up, you can see how good things look. The final plug welds were put into place and smoothed out as well. |