Stuffing a Rust Hole!

Today I just recieved a patch panel for my 1960 T-Bird. The left front fender had a big rust hole in it. The previous owner stuffed it full of bondo. So now I am going to cut it out and replace it with steel. Does anyone have any tips, suggestions as I have never done this before. Any help would be awesome!

 

First thing I would do is vote your city council out of office..

 

The rust has probably weekend the metal out past the area where it's obvious. Make sure you have enough healthy metal to weld to by checking out the back side of the chunks you cut out. Also, prep the metal well by removing all rust and scale before you start welding the new panel in.

 

And if you can, work with the body seams. They hide screw-ups better than flat panels.

 

Hey blurr,

A photo of your problem area, on the fender, would be a great
help in givin' advise-

What kinda welding equipment do you have to work with? This is
going to have alot to do with where you cut out and reweld the
rusted area. Can you tell, are the patch panels any where close to
looking like they'll fit without major rework? This is usually the case
with most patch panels on the market, not all though!

S****ey Devils C.C.

"Meanwhile, back aboard The Tainted Pork"

 

UH Uh.... Then what?

 

Right On. I will try to get pics up tonight. Thanks

 

i had the same problem... this is a thread i started showing the work i did. I hope it helps.

http://www.jalopyjournal.com/forum/showthread.php?t=203030&highlight=shark

 

1. Use the search function. Key words: patch panel, welding sheetmetal, warping.

2. There are several good tech threads; "a patch panel from start to finish" is one that comes to mind.

Good luck and post some pics!