Gentlemen: I have a 1978 FJ40 that has rust bubbles under the paint on the visible part of the body. Sanded down with grinder to clear metal, treated with Phospho a couple of times, used bondo filler(had a couple of holes about the size of a pencil eraser, primed with Rustoleum primer a couple of times and then painted with several coats of Rustoleum paint. I think these will be OK. However, under the body, I have some rust holes in the tub and other areas that need repair. The frame is solid and there is no rust problem with it. I am not a welder, but I also do not have the money to pay someone to do this work for me. Besides, I really enjoy working on the rig myself. As I mentioned, I am not a welder and all of this cutting and welding will be done upside down while on my back and the thought of the hot metal getting on me is not very exciting. What do I do? Can I derust these areas as much as possible, paint with POR 15 or Rust Bullet and then pop rivit new metal over these areas? Or, can I derust as much as possible, sand down to bare metal as much as possible, use POR 15 or Rust Bullet and then use fiberglass resin with matt to cover these areas. Certainly one of these would be my best options as I don't weld. BUT, I am asking for your advice. Do I really need to save and buy a cheap welder and some scrap metal and get under there and do my best and patch as best I can and then sand, prime and paint? Please give me some advice and some of the options and some of the ways that you have approached a similar situation. Thanks so much in advance for your advice. IH8Mud is the greatest.....
