Thankfully I have now finished, the clam is back on, everything works and it's ready to drive again. Just in time for this nice cold wintery spell of weather!
I had to do some little bits of fibreglassing under the headlamp area before refitting the clam.
Didn't worry about it being a really tidy job as its invisible when the car is assembled, just wanted to add some strength back into the area. Some filler and a spray later
My wife ventured out into the cold to help me lift the clam back on. I managed to get everything buttoned up before dinner but my garage looks like a bomb hit it now.
I've got to look at this again this weekend, the front clam isn't properly aligned with the hinge cover panel on the nearside. The captive nut had come loose so the bolt at this fixing was stuck in place, can't take it out or tighten it and clearly didn't line it up properly when I put it back on.
Spent some time this morning loosening off all the front clam fixings again and getting it aligned better. After that I took it out for the first drive since the start of December. All seems well, icy cold air con too so I'm happy. I thought the air con had stopped working the other day when I tried it on the drive but it seems fine now.
I have to say I was relieved to hear and feel it working on Saturday. My working theory is when I tested it on the drive the other time the ambient temp was just too cold.