Thanks guys, will get a spot weld drill and see what i can do. Can i install the new panel with rivets? Will it be very weak?
the lower crossmember is structual eh baguete (and needs welding) but is,nt yours undamaged ? and cant you cut the nearside headlamp panel and flitch panel complete from another car and splice the whole upper corner on ?
ah just seen pics in your blog, id do as frank says, try and get the whole corner, including some of the inner wing if needed, and then weld/rivit it on, you should be ok riviting if its not structural, or if you cant get the whole corner, get the complete front panel from the parts store, and cut off the part you need, i.e. the headlight surround
i would have thought riviting a non-structural piece in wont be a problem, not sure what the MOT ruels are in lisbon tho, but in the uk, aslong as its 30cm away from any steering or suspension parts and its non structural it SHOULD be ok
i just used a normal metal drill bit to just start to get through the top layer (the metal starts to change colour) and a hammer and chisel to finish it off...then a go over with a grinder to clean it up.
The headlight surround doesnt have many spot welds as standard so even a garage would probs only take a few mins to do.
only other thing is to try and mark where the old one is before you cut it off to make your life easier...only mentioned the garage option are you said you didnt have a mig but yeah dead easy to do tbh.