Here's the new aftermarket lower fender extension after Terry cut it in half and moved it over 1/2" or more, and then spot welded to fit the original GM fender:
On this picture, notice the gap where the bars are--there will be a piece of metal butt-welded to fill the gap. Also notice where the new lower extension had to be cut and welded for proper fit. Notice the clamps Terry uses for proper alignment to the original metal:
Here's the proper alignment and fitting after the work is done:
If you're going to use aftermarket sheet metal, regardless of what company manufactures, plan to have a professional sheet metal guy handy for proper alignment. This photo shows just how much has to be filled in and welded with metal. I paid $85 for this lower fender extension and you'd think it would have fit a lot better, but you can see the 1/2 in.+ gap.
Now I understand a lot more about aftermarket sheet metal and what a nightmare it can be to fit original metal. Terry's an excellent sheet metal guy and I'm glad to have him on this project.
I'll post pictures of the completed fender later this week after Terry finishes up. Stay tuned for Part II.