We removed the fender emblems and fitted the fender patch. We marked the top of the patch and made sure it fit.
After marking the fender itself, We drilled guide holes through the patch and the fender to allow us to have a reference once we removed the patch to cut away the bad portion of the fender.
We dry fitted the fender to the car with the door back on. We wanted to check the alignment and the gaps. They looked good so we welded the patch on.
Next I moved to the interior of the fender. There are two partitions that serve to keep water and debris from getting to the headlight / front of the fender and one that is suppose to keep water and crud off the end of the Outer Rocker. Each of the partitions were rotten. I did not realize these parts even existed until we started on the fender repairs.
There are rubber seals that help with the job of keeping the two area mentioned clean but they had failed too. Since I did not want to wait and order these parts, I decided to make them. I am holding one of the shields in my hand and you can see some of the holes. 
This is the one I made. As with all the parts I am putting back on, I have used a bed liner spray to seal and protect the internal body parts.
The wheel well after the bed liner spray.
This is the front of the fender before the shields were re-installed
And after
Now it was time to move to the front valance and grill area. I spent a bunch of time banging out the dents that had been gathered up over the last 40 + years of travel. It seemed as if there was some off-roading too!
The engine compartment was also coated with the bed liner and the new battery tray was ready to be installed.
We started reattaching the wires and getting the area ready for the motor. It was due to arrive next week. ( slight set back from when we first thought it might arrive)
So at the end of two days and about 21 hours with the car, we have a nice looking, unpainted fender and we are getting closer to the end. The birthday is quickly coming...will it be done???