After fixing the drip rail on the drivers side, the other side is already suspect for similar damage. The owner was hoping we could get by with leaving the passenger side alone. There was some deep pitting in the drip rail, and some visible where the seam sealer was removed. Found two small holes in the outer part of the drip rail, which I thought could be welded up if I had to........but where the inner part of the drip rail spot welds to the underside of the sail panel, I could feel the telltale signs. The metal had swelled up, giving the indication of some rust scale lurking between.





Note pin holes:





The owner really didn't want to cut this side open, so what's an anal-retentive guy with a bunch of raw sheet metal to do? So I waited for him to go on travel for work, called him up and then told him the bad news.







Replacement fitted and welded:





















There, all put back together, before he could protest too loudly