Rust Database

[herring]

Now that is a proper repair.  Looks great, and that's what I wish I could've done.

I used to be a proficient stick welder, but my skills and eyesight have faded, so I chose an easier option and cut sheet metal to paste on top using JB Weld/Kwik-Weld.

I posted my process in this thread.  I'm just responding to point out that there are ways of dealing with the rust that don't require a welder or the skills to use one, just a grinder and the willingness/ability to shape sheet steel to fit.  These cars are getting older now.

I 100% agree that whatever rust you see, will be much more significant once you get into removing it.  Be prepared to cut out and patch a lot.

[Donny1940]

15 minutes ago, herring said:

Now that is a proper repair.  Looks great, and that's what I wish I could've done.

I used to be a proficient stick welder, but my skills and eyesight have faded, so I chose an easier option and cut sheet metal to paste on top using JB Weld/Kwik-Weld.

I posted my process in this thread.  I'm just responding to point out that there are ways of dealing with the rust that don't require a welder or the skills to use one, just a grinder and the willingness/ability to shape sheet steel to fit.  These cars are getting older now.

I 100% agree that whatever rust you see, will be much more significant once you get into removing it.  Be prepared to cut out and patch a lot.

I saw that post. I think it turned out very good. Definitely 10x better than I would have imagined a JB weld repair to turn out. 

 

I'm not totally convinced the amount of effort I put into this was worth it for a 13 year old Fusion, but once you cut the car open, you're kind of committed. I won't knock what you did.