Anthony wrote:
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Originally Posted by ahleeds
I always cut the new patch first then lay your new peice over the rusty spot and ... cut out the rust
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Whereas ozm29c John Wilson wrote
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14...determine the extent of rust damage. Once you have cut the rust out of a particular area, then and only then is when you will know where to start your repairs
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I've cut and shaped patches only to find that the rust extends further than I realised. Rusty spots usually turn out to be larger than they initially appear from the outside. Perhaps the best method is a compromise between the two ideas - cutout almost to the edge of the rust and when you're satisfied that both sides are almost clear of it - make and shape your patch a bit oversize and then overlay it. Drilling and using pop rivets or self tappers at the overlap and then saw or slit is also an idea but would need a couple of mig pulls to fill each hole that remains.
Alex