body work for a newbie

[ozm29c]

Originally Posted by cantankrs

Anthony wrote:


Whereas ozm29c John Wilson wrote


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

Alex,
Once you become an 'Artiste' with MIG welding techniques, Making replacement patches to fill holes is an easy task. Also MIG welding is very forgiving and it is easy to fill holes/gaps that either exceed 1mm or holes that you have made an 'error of judgment' shaping the patch.
I would not get too flustered about finding more rust behind a section that you have just removed. Here are some photos of my weasel repair to give you an example.
Cheers
John W.