Quote Originally Posted by 35WINDOW View Post
Have you considered using a Bonding Adhesive like they use today in Auto Body Shops like Lord Fusor, 3M or Duramix? You wouldn't have distortion, and it is as strong (or stronger) than Welding, and is designed for Sheet Metal-in fact, Audi will now disallow structural Body Warranties if the Body is Welded-just a thought-

http://www.lord.com/Products-and-Sol...roduct.xml/133
No not yet. I would have to modify the mating surfaces to make them flat against each other. This would not be a big deal considering the amount of work any route will take. If I flattened out the mating surfaces and bonded them into place, would I then fill in the crack where the fender meets the body with a glass type filler like Don mentioned above? If I did it right, the crack would be very close and hardly noticable. It seems that I would have to cover the crack with some kind of filler to keep the paint from cracking.