Metal smoothing...

Last night cut out the core support and some of the engine bay...
http://i138.photobucket.com/albums/q...h_cb91ec7a.jpghttp://i138.photobucket.com/albums/q...h_a0e7e36b.jpghttp://i138.photobucket.com/albums/q...h_ea35114a.jpg
http://i138.photobucket.com/albums/q...h_7022cc85.jpghttp://i138.photobucket.com/albums/q...h_e027c9bc.jpghttp://i138.photobucket.com/albums/q...h_95e95e17.jpg

Once I grind down the sharp edges and make it all square... Any tricks or tips to smooth the metal out?

Also with the area's I cut out in the engine bay... Best way to take the sharp edge off the metal? Hit it with a cookie disc? Or different trick?

Cookie disc or flap wheel would work well. I used a flap wheel/grinder disc when I took out some of the ugliness of mine.

hammer and dolley to make the area flat, lots and lots of tack welds "stitch" the replacement panel in place

Agree, hammer and dolly and patience.
Use angle grinder to knock off all the really sharp edges so you dont destroy your flexible wheel when you go to smooth out the edges. Use a sheet of bristol board to trace out the exact shape of the hole and use it as a template when you go to cut your 0.035 steel sheet. If you want to do it quick and dirty, cut the steel slightly larger and overlap the edges. Welding on one side, and seam sealing on the other, by doing this you'll be less likely to warp the panel when you stitch it together. Dont run a bead any longer than 1/2" at a time in each area. A panel that big is going to warp and distort. Bead rolling the panel would help mitigate that.

Scott rod panels work real well, did it to mine ill get you some pics

i have scottrods also.

but if thats not your thing, you can buy replacement panels that are smooth already

Scottrods is way simple and not bad on price vs. labor of all the time invested.

Not sure, but I think he is wayyyyyyyyy past the engine bay inserts now...