Hi Mini Waco,
If you look on youtube, there's videos of minis being manufactured. What they did is hold the floorpan in a jig and welded everything else on. It's 1950's technology. As a result, every mini is slightly different which is why replacement panels rarely fit spot on. On a shell re-manufacture, what you do is use the shell as the jig. This means cutting the least out before welding a replacement panel in. It's important not to allow the shell to lose rigidity and twist.
In the haynes manual, there are some measurements to check for shell alignment, I used these when I was welding in major components like the boot floor. I also took loads of measurements like suspension mounting points before I removed structural panels. Also, to ensure everything is square, it's a good idea to measure diagonally. I did this from the floor X member (original part of the shell and not replaced) to the replacement heelboard (back bulkhead) before it was welded in.
Hope that helps.
Not much done recently. I've fitted the seam covers though. I used 4 clips per seam, bonded them on then seam sealed. I've been told by "those in the know" that the paint will crack. Time will tell I guess
Flatted the plastic arches
And primed them with this
That's all for now
Pete