Unfortunately I do not have photos going back to what I started with. I originally roughed out the area by cleaning off the existing paint and rust to determine the extend of the rust. For that I used the grinder with a flap wheel which removes the paint fast and efficiently, while minimizing damage to the existing surface. The belt cover was removed to get full access of the damaged area.

Next I picked the correct gage of metal required for the repair. This can be purchased at a metal supplier, automotive parts supplier, or hardware store. I took rough measurements of the material that was required, then began to cut it to size. For now it was just a rough layout, the exact size can be finalized after. Using a mix of concrete blocks for weight, wood blocks to help achieve a smooth bend, a hammer, and adjustable wrench I formed the main bent from the horizontal to vertical portion. During the bending process I made sure the metal I was bending matched the contour.

Once satisfied with the main bend, the sheet metal was cut into two sections which I found was the easiest to match the multiple angles of the deck. I started with the more complicated piece first, using the grinder with a cutting disc to make shallow “V” cuts on the horizontal portion. This will allow for a smooth curve while keeping one solid piece of metal.

The piece was then slowly formed using the block of wood and a hammer, matching the curvature of the deck. Some material was required to be removed from the “V” cuts to help achieve a tighter curve.