I found a solution to the front quarter panel body pieces. I’m building the pieces out of steel sheet metal and square tube that is welded to the Lancia chassis. These pieces will be skinned in thin steel as shown in the second picture below but represented by a manila folder that I am using as a template.

I’ll use easy to shape polyurethane foam blocks on the leading edge to continue the contour of the wheel arch down to the bottom rocker panel. With the foam blocks in place I’ll cover the whole assembly in fiberglass, including the outside surface of the steel box section. After shaping and smoothing the fiberglass I’ll pop it loose from the steel and bond it in place with 3m panel adhesive.

This method will allow me to build both sides with very good accuracy. It creates a solid sub-structure that is welded to the chassis which will make the body latch very strong. The relief pocket for the door extension allows the door to open fully without interference.