with most of the panel cut away, and the rust swept out, the upper inner structure of the frame head can be examined, looks savable, with some welding in of new metal along the lower edges.
looking at the frame head support bracket, commonly called the Napoleons hat, due to it's silhouette, the lower edges of that need to be re fabricated along it's lower edges, glad about that, I don't fancy totally replacing that as well.
with a coat of krust painted inside, the rust pitted metal turns an even shiney black.
these are 2 of the four bolts that hold the front suspension assembly to the frame head.
you can make out the bolt receiver tubes inside the frame head, I could fix this area a lot easier if I unbolted the front assembly, but I need it there as a reference point when I weld on the base plate.
the very reason to wear workshop PPE, I always wear a mask, goggles ear defenders and a baseball cap, Ears, eyes, nose and hair. this cutting disc shatters and the missing piece struck my mask and bounced off into a corner of the workshop. The cut was in a tight space and put uneven pressure on the disc.
once the grinding has been done, I can fix the napoleon hat on and weld it in, then I can bolt up the frame head base and weld that in, I'm counting myself lucky that the frame head structure is sound, there would be a lot of work replacing that as the front suspension bots to it and it's alignment is critical.
so the new parts fitted up ready for welding in. OK, I admit it, I'm just as surprised as you are that they all fit. The heavy bottom plate is supported from underneath by a jack, is bolted at the edges of the napoleon hat.
the main thing to remember here, and one that I am grateful for is, the frame head itself, that great nuckle head, looks like a gloved fist at the end of a sleeve, is un-moved, welding in the base plate will only make it stronger.