Well folks, it's 9 months later, and I have a whole car again. It was slow going: no driving because of the pandemic meant no real urgency, some anxiety about my ability to do the job well didn't help, but mainly it turns out that it just isn't as fun the second time around.
Photo dump (of the things I remember to photograph):
Here were the earlier days. The hood edge was crushed a bit and there was no hope of pulling it out and I wasn't going to just use filler. So cut and welded first, then filled. I probably applied and sanded off filler 8 times trying to get the curves right, but (spoiler alert) it just wasn't cooperating. Got lucky and found a nice headlight bucket on eBay for a very reasonable price. Couldn't find a fender, so I beat it into the best shape I could and welded the sugar scoop to it. The coat of epoxy showed just how much work I still had to do. A ton of sand-fill-sand on the fender, but it got there in the end. The wheel arch and the curve where the fender/headlight come down to the air dam were the biggest challenges.
Time jump to late March, and I was feeling pretty good about the progress so sprayed both the hood and fender with epoxy to get ready for some final block sanding. Put too much paint on at one time, so I had to clean that up and do some touchup work on the wheel arch. Worse: after spraying the hood, I could see a flat-ish spot that I had felt when sanding, but talked myself into thinking it wouldn't be so bad. It was, so I stripped it all off and started over. Realized part of the problem is the hood on that side had kind of collapsed, so I shimmed it with pieces of steel bar (I had to do something similar on the other side a few years ago -- my poor hood is kind of a horror show). A few more rounds filling and sanding, and it finally came together.
Let's talk paint. The guy I bought the paint from originally no longer sells that brand, so he had to try to match it. It wasn't great: I had to go back a second time to and have him tweak it, and I still wasn't confident in it. He gave me some extra black so I could adjust the tint myself. Tested on the old headlight bucket (good thing I saved it!). The dark half on top original, the light is what he gave me, and the blotches are my continued adjustments. Fortunately, I also had just enough of my old paint for one coat at the end. Still, there was a lot of hand wringing on my part about the color and a real concern I'd have a hood and fender that didn't match the rest of the car. Did a pretty okay job putting the paint on, though!
Quick break for a "while I'm at it" job. The detent roller pin on the door hinge popped off a couple years ago. Not a huge deal, but an annoyance, and I already have the car apart so I should fix it now. Turns out you can't buy a replacement pin and I didn't want to get a whole new hinge if I could avoid it. Went to the nuts and bolts section at Home Depot and found a stainless bolt that fit the roller. Ground down the old treads enough to get the die to fit and cut new threads, then tapped the hinge. I don't know about longevity, but it works for now and only cost about $1.50.
And finally the bumper. It twisted and buckled in two places in the collision. I used a bottle jack and 1x1 to get it back to the mostly-proper width, then wedged it under my engine hoist to fix the twist. It still needed more convincing, and I figured I had nothing to lose, so I beat the bejeezus out of it with a hammer to do the rest. Did a lot of hammer and dolly work, filing, and sanding to fix it, and had a couple spots that I just couldn't correct. So I turned the bumper upside down and now they're on the bottom. Had to weld in a couple of new nuts to make it fit right against the car. Polishing was a Sisyphean ordeal and I got to the point where I was only making the things I was trying to fix worse. So I called it.
The finished product: