I've got to replace the toeboard on the Dyane. I've seen it done before and I think I know the basics, but any advice would be much appreciated. I'll be doing the inner and outer panels using an ancient MIG welder whose use I am barely proficient in. But I can practise beforehand on bits of scrap steel. What's the best way to rustproof the finished job?

Seams - http://www.ebay.co.uk/itm/TETROSYL-BRUS ... 3cd1128e5c

When do plan to do the welding?

id join the new inner and outer toeboard together before welding them in.

Are you making the panels or buying them? The ones Ive bought in the past need quite a bit of work to make them fit as they are basically a 2cv panel with a hole for washer and a couple of brackets to fix inner wing/mudflaps and the cut out for sills is wrong shape and the top of the outer is folded out as per 2cv but this is not how dyane outer panels are fitted.
Take your time matching up before cutting out old panels. Ive done 5 myself and they are not as easy as a 2cv
Cheers
Boggy

I sent some emails to Ken who sent some bits of metal to me which I left in the car outside Russ' workshop and that seemed to do the trick

Seriously, I do recommend Ken's home brew toe board. Russ and I took the body off and flipped it upside down and I believe Russ plug welded it into place.

I must get some pics of this up!

I hate welding cars. Never done a Dyane (not worth it) but I reckon taking the shell off and turning it upside-down is the way to go. I hate welding cars. Ive done a 2cv lower bulkhead with the shell still on the chassis and what a cock of a job that was. If you can get away with letting in patches then do that, i hate welding cars, also, if the bulkhead has had it then its probably a fair bet it wants more than that. On a 2cv by the time the toeboard needs repairs you're looking at A posts, sills, floors, rear seat box ends, rear heels, and so on. I hate welding cars. My advice is dont. Fill it with builders foam. That doesn't rust.

I replaced mine and used all the original points (floor pnels - master cylinder area) as reference before I changed them. Took my time but no big drama.

P.S for Russell - I like welding cars better than doing plumbing in a mouse infested loft.

It may be easier to turn the body upside down.

Would you like some help.?

If you hate welding cars so much... than bring them to me and I do it for you ... I dont hate it - I love it

Crikey ... thanks for all the advice, folks. Looking at it, I'm not sure it's bad enough to justify replacing the entire toeboard yet, so I might patch it to get an MOT and do the job properly next year. If that meets with general approval, that is.
Pete, thanks for your offer of help! I would certainly appreciate moral support and advice ... I'll PM you when I work out when I'm going to do it. Tea and/or beer is on me.