I have done a bunch of front end hit on toyota's, mostly deer damage.
One of the most important things I can think of is OME parts for your core support, apron, innerfender and what ever else you have damaged structurally.They seem to fit soooo much better and are more structurally sound then after market, I would also use OEM sheetmetal also but thats for cosmetics and not as important.
Another thing is to make sure everything is square. Find two points that are the same on each side of the firewall and two that are the same on each side on the core support.Measure straight and diagnal from these points.
Get all your stuctural parts prep'd(hole drilled and sealer ground), pieced together and squared up before you spotweld anything. You can hold everything together with some self tapping sheetmetal screws and clamps.
I have always used snap-on(bluepoint) spot weld bits. They may be a little spendier but don't damage the metal underneath as bad as most, they just leave an 1/8th" hole.
Also, make sure you get some corosion protection on the back side of your spotwelds.... Rust is bad!
I have been out of the bodywork trade for a year now and after thinking about it and writing this down, I realize I don't miss it a bit.
Shoot me any more Q's you have.
Enjoy:beer:
