OK, here's how we did it. First using the Dremel with reinforced cutting wheels we cut out the nasty bit of welding. Cleaned it up using a file to get the edges smooth. Then cut a piece of steel of roughly the right size. Then using the MDF cut two pieces out and shaped the curve of the arch in them. Then used the MDF as a template to cut out the curve in the steel. Clamped the steel between the two pieces of MDF so there was about 10mm sticking out and beat the crap out of it using the hammer. This made it a right angle in the steel in a curve as well. Then using a saw, the Dremel with a sanding drum fashioned an exact fit with a piece of MDF. It was a bit big sticking out and had no curves, so using the sanding drum copied the curves and finally used sandpaper to make it perfectly smooth. Again fitted the steel to the template and bashed it. This transferred the curve on the MDF (which matched the arch exactly) to the steel. Lastly, a final bit of grinding with a wheel it fits like it was made to be there, which it was we suppose?

BUT, sanding MDF makes very fine particulates which can be breathed in and get everywhere. Wearing a mask would have been preferable but we did the sanding outside.

Non reinforced cutting discs on the Dremel seem to have a tendancy to shatter so be extra carefull. I never put my face in the line of spin just in case. The reinforced wheels haven't yet exploded but wear down very quickly and at $25 for six, use them sparingly.

Eye protection is a must. The angle grinder gives off some sparks and they have a mind of their own as to where they will shower. You may feel like a complete twat wearing eye protection in your own workshop but by crickey I'd rather goggles than no sight.

If you use a hammer and dolly make sure their faces are smooth. Use very fine wet and dry to rid them of any burrs or crap. Any flaws will be transferred to the metal you are bashing. Read a couple of books about sheet metal fabrication.

Bought myself a welder to weld up the panels I am making. Taught myself how to burn holes quite succesfully. Welding two bits together is very different however. Three different settings mean a lot of variables to try. I finally think I have a suitable setting and having practised on several pieces of scrap, I'm now ready to tackle the car.

Large radius pipe.

Quite a sturdy pipe that's not easily damaged when whacking full force with a hammer.

Small radius pipe.

Much the same as the large radius pipe. Easier for making tighter curves.

G-clamp.

A must we reckon. Clamp something to the bench and it allows both hands free.

Floor mats.

OK, pile them up and they can act similar to a sand bag.

MDF.

Easily workable wood that can be shaped with sand paper quite quickly.

Angle iron.

Makes forming right angles easier. Clamp the steel under the iron and simply bend it by hand. For a sharp angle use the hammer.

Hammer and dolly.

Used to hammer out those little lumps and bumps. Also BIG lumps and bumps as well.

The Dremel.

A tool we haven't used as much as we have over the last few weeks.