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Even though I replaced the rot in four stages to limit distortion when I checked the mudguard it was slightly twisted. I made sure the frame was perfectly vertical then marked the centre of the frame before running a laser along it. At this stage, without the second skin in place, I could just pull the mudguard by hand until it was straight before I fit the inner sections.
The inner sections were fabricated and tacked in place, these I could do in one piece so will help with the strength.I decided against trying to put a rolled edge on the inner panels like the originals as that is what trapped the mud and started the corrosion in the first place. I’ll also spray some under seal under the mudguard to hopefully prevent any more rust in the future. I tried the cast aluminium sections on and they sit fine and there were no more problems with the mudguard alignment even once the seam welding was done. One of the fiddliest bits to do was the wedge shaped section right on the end of the mudguard, it has two ridges and curves in three directions so a rough approximation was tacked in place and with some gentle tapping as I went persuaded it to conform, a smear of filler helped.