In a much earlier post, I mentioned the problems I found in the right front fender area around the headlight. Well, I just tore into it and took out all the wire screen mesh and bondo, but not much was left when I got it all off. There was just a big hole where that corner of the car was supposed to be. There was another problem, and that was the wheel arch was dangerously close to the tire; much closer than the other side. Seeing as I am trying to make this a functional race car, I had better not overlook a potential place for tire scrub. A certain amount of asymmetry in the body is characteristic, but the right tire was actually outside the fender on the right side and well inside on the left. Other Mk III Couriers have this problem too, possibly because the fiberglass molds were getting old by that time and may have become distorted, who knows?
Anyway, I have put together this gallery to show the progression of rebuilding that corner of the car. Hopefully the pictures speak for themselves. I will just say that the dark brown goo you see in many of the photos is epoxy mixed with phenolic microballoon, and what looks like pieces of wood, is actually balsa core.
Elva Courier MkIII Restoration Blog 