small rust section...reasonable solution?

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Joined
Jun 26, 2017
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Location
hanover, nh
With no practical welding experience I find myself wondering what so many before me have asked.....

the one spot of rust on my truck is fairly inconspicuous, right rear quarter panel under the bumper. a little smaller than fist size....

should it be welded with a piece of sheet metal? can I do it with MAP gas?
or fiberglass it....?

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I'm no rust expert, but what I've encountered with my truck is that what you can see versus how big the rust spot actually is, is usually around 2-3x. So you'll need to replace more than what's visible. I've used sheet metal and a MIG welder to do mine. Stock is 18 gauge, I've used 16 gauge for most repairs I did, the thicker stuff welds a little easier. 18 would probably be easier to shape.
 
My neighbor has an arc welder...
too tough on body work?

Yes. MIG, or a skilled hand on a TIG or oxy-acetylene torch is required. I had a little rust in that area so I chopped the whole section out, made a plate to fill the base of that cavity about 3" higher than it was, that was an easier fix than patching it & gave me clearance to brace my tube bumper back to the chassis in a much stronger fashion than it would have been if I was working around the sheetmetal.

Cheers
Clint
 
who does one go to for a small patch like this? Like a muffler place or a body shop?
 
MIG or TIG as already mentioned. TIG is better because you can keep the heat down to almost nothing. You can litterally weld a beer/soda can back together with a TIG, it is the only kind of welding you can do this with. Body work is definitely not the place to start learning to weld. However, for body work you do not need a big machine, a 110v MIG will do the job fine. For MIG always weld with gas, flux core wire is not good and only for using outside where wind will blow away your shielding gas.

Take it to a body shop because you also need painting and color matching. Most body shops do not deal with the inside correctly though and leave the metal/welds raw which leads to rusting again. So you will want to check inside the panel after they are done or speak with them specifically about this before work is performed. You can POR15 or Rust Bullet inside the panel after they are done and that will take care of it for a long time.

Here is something that is a bit of a myth for people who do not know body work. Body filler is not a bad thing at all if used correctly. Almost every body shop uses it, including high end restoration shops. Some car manufactures even use it as vehicles come off the assembly lines, for reals, no joke. It is NOT meant to fill holes or be thicker than say 1/16-1/8". It is NOT meant to be put over rust. It is meant to smooth out panels and deal with minor imperfections. I have done $100k restorations where we had over $25k just in the body resto and paint so am real familiar with all this and learned a lot on those projects from guys that are true pros.

Cheers
 
who does one go to for a small patch like this? Like a muffler place or a body shop?

Auto Body shop is your best bet, however it is getting harder and harder to find ones that just aren't used to replacing parts as to repairing items. Tell them you want it repaired not just patched as some shops will just quickly weld a patch into the whole, while there may be more rust in the surrounding metal. Best to cut out any rust in the surrounding area so you are welding new metal to good old metal. Then make sure they apply some type of sealer to the back side of the panel as well as paint the front side.
 
I have cheap quarter panels in stock where you can cut out the piece you need to replace so the result will be a minimum of bondo,big chance that you will have the same issue where the seem is in the rocker panels and both lower wheelwell flares.Check for bondo and remove as needed before you head to the bodyshop.

Joe
 
I have cheap quarter panels in stock where you can cut out the piece you need to replace so the result will be a minimum of bondo,big chance that you will have the same issue where the seem is in the rocker panels and both lower wheelwell flares.Check for bondo and remove as needed before you head to the bodyshop.

Joe

Joe, I have seen and held your replacement panels. I would describe them as cost effective rather than cheap.
 
When in doubt cut it out! For the cost of that 1 repair you can buy a MIG welder. I have a 20 amp 120v machine works like a charm. For areas I have to form a patch to I like 20g hr steel. Lil holes need to be opened up and rust removed. Otherwise your just buying time. With that hole it ain't likely 1 patch you need. How's the inner +outer wheel wells?pull the tail lite if the metal below it is rusted deal with it all. Please don't put bondo on rusty metal

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Pop rivets work n non stressed areas. They make that 2 part panel epoxy now, some cars have panels glued. Last time I chckd, a special dual "applicator gun" was necessary. Maybe they make the stiff n smaller packages now.
 
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