Bad rust? Where would you start?

[riverguide]

While waiting for a few parts to arrive for the cruiser I figured I'd jab at it with a screw driver. I had made a hole a few weeks ago where the mud flap was. So I hit it a few times today and starting chipping away. The pictures below show what I ended up with. My question is where would you start with this issue? Get another panel? Try to repair? There is a lot there and I haven't hit the rest of the spots on the wheel area yet.

Thanks.

 

[D'Animal]

It is pretty clear where you start with a project like that.

The real question is, where do you stop?

I would keep poking it and get the rusty areas identified. If you can do metal work, weld in some patch panels.

 

[copasspupil]

Someone once told me that the mount of rust you see is only 25% of what is really there. Search there is way more than you think.

 

[onemanarmy]

I've got rust similar to that on my 55, and have most of it identified. Would my (and the OP) best bet be with some sort of bondo, or something similar? I will be doing this in my yard, and in that pos. on the vehicle it would be kinda hard to weld in some patch panels (for me anyway) Would fiberglass be better?

Thanks

 

[1tontoy]

You could try some POR-15 Putty....? I've never used it or seen it used, but if you don't want to weld....it seems like a good fit for this situation....

 

[riverguide]

Thanks for the replies. I know there is more, that is why I stopped. I was curious as to what to do for this spot before I move on...or rather, the entire fender once I am done poking.

Is there something I can cover this spot with until I can get to it? I thought about sanding it down or grinding this area down for now and covering it with something...but the metal behind the main sheet metal is showing. A few rains won't hurt between now and when I get it fixed, maybe a few months will it? Any other ideas?

 

[bosscat800]

The only way to get rid of the rust is to replace the panel, or panels. You will find that the inner structure is going to be rusted out also. As far as waiting, wont matter, it is just going to keep working, the rust that is. First you need to find out how bad it is, second decide if you need complete panel replacement and inner structure panel replacent or just patch panels. Could turn into a BIG job!!!

 

[Southeast Overland]

This will be a big job if you do it right.

First you need to know the FULL extent of the rust. It will be much more than what you see now. Get a couple of wire wheels, flap discs and screw drivers and knock all the rust away. When you think you have it all try again...then one more time. You will need to have solid, thick sheet metal to weld to. Thin sheet that has been rusted will be a PITA to weld to.

After you do that post up some pics. You might be OK welding in patch panels, might need whole new panels, might need a new body...or might be on your way to a buggy - we will need to see the extent of the rust before we can say much else.

 

[riverguide]

Thanks guys. Appreciate the input!

Until I find all the rust, cheers!