Re-skin the Engine Lid of a VW Bus

Here is the damage that sparked my deck lid repair project. After attempting to remove all the paint off the metal (one of the last pieces), the engine lid surprised me. It has about 1/3 think of Bondo covering it.  This was pretty messy sanding work.

I purchased 20 gauge sheet metal to replace the metal on my engine lid. I sent in the measurements so that it is perfectly square upon arrival.

Specs:  17 1/2 x 37 7/8 - 20 GA (0.36) Coled Rolled Steel

 These measurements are not set in stone until I've had time to wrap it around the lid frame.  I will update after this process is done.

This is to show the fit of the sheet metal from the bottom view.  I am going to remove the tack welds and separate the frame of the lid from the top so that I can cut out the license plate area.







This is the condition of the engine lid.  I was trying to pull the metal along the sides with a stud-puller. Originally, I thought the metal was two-ply, but it was not.  So, I decided to go the route above, creating a new skin.