if the ruist hasnt gone straight through then just use a grinder to get it out. those places that has gone through the cut it out and weld pieces as mentioned above.
the most expensive part of rust repair is the reshaping of metal. it takes time and patience to shape the metal right.
when cutting the holes as people100 said hit the area back a bitso that it sinks back. put the new piece over it and ONLY do 2 tacks on either side (that way if its wrong in any way its easy to grind back off). once satisfied with the way it sits continue to weld round (what i recommend is to weld spots on opposite sides till they meet, ie, spot on top then below, then next to first and back to bottom one and so on. that will prevent the warping people100 mentioned. once this is done grind the high spots back and get it as smooth as possible (not perfect so dont try). after that where the welds are just tap them back to recess them a little and bog a light coat, primer and BAM
the most important thing to remember is PATIENCE cause rust can send you insane thats why im getting my mate to do it for me, but he is a panel beater
Mon, 18 October 2004 11:41
thats why im getting my mate to do it for me, but he is a panel beater 
