Looking at that one frame rot I think to just squint and rust convert it and deal with the outer skin, the gutters look ok so save them and use on the cover panel. Good progress so far 😁
edit.. handy tip is to not have the repair pieces square edge, just nip the corner with snips so it triangles it I tiny bit, I was taught this 100yrs ago, it's something with heat expansion binding up..

Will say that there wasn't rust proofing back in cortina and escort days so that inner frame would be bare since new and began rusting in the car yard. So I'm saying it might not be a sealer leak but just atmospheric moisture especially winter times when the car is loaded with humans breathing air fogging the glass and also any metal it sticks to including pillar panels !

I've not really noticed a difference either whether the corner is trimmed or not, it sometimes helps fit the gap a little better !

Its coming along really well. I'm suprised how good condition your cuts from the donor have been in.
Chalk and cheese!

I really need to get to the nationals for a look, the idea of not having a car to take along puts me off though. Maybe I'll load the TD onto a truck in the coming years.
 
Saw this one on Gumtree WA recently, thought of your wagon straight away, they would've made a nice pair. The car was surprisingly solid and rust free despite its appearance and came with a spare donor car aswell.
 

 
 

So after a few months off I finally got back into it.

Suffering a bit with post holiday blues and struggling with hayfever/headaches of all things....

That said, the clock is ticking, and Fast.

Took the flap disc to the front of the guards. I new there was bog, as it had cracked along there, but wow.....

I have a donor cut from one side, it needed a lot of panel work as the front had previously had a hit, the end product seems to fit well.
 
The other (drivers side) I will make from scratch.

Pics show the story.

both the headlamp bowl and outer gone, looked pretty crusty.
 
I think the previous owner may have been a sculptor, with the skill needed for that bog.
Yes, you have made good use of the donor car, I'm amazed the panels it gave you were in such useable nick.

Still working my way around the front windscreen section and onto the N/S A pillar.

I will need to get back to the front guards as I needed to wait whilst the seam sealer dried on the inside.

A pillar needed to be separated into sections.

The rust cut i had on this side was from a S2 which has a different profile around the top of the door. The drip rail/chrome trim is also straight not curved down. So I reused the original drip rail and reshaped the repair section to S1 style to match the driver's side.

As usual, all was insides were rust treated and black zinc primed before welding back in.

Also smeared some bog on the drivers section into between waiting for coats to dry.

Having not welded in 2 months, its taken a bit to get back into it.