If I had to fix that without welding I would take the door off, grind and wire brush away the paint and bondo. Kill the rust by painting with POR15 inside and out then build up a new corner with kitty hair and bondo. I could do it on a $1000 bet but it would be easier to weld it. Sometimes you can pop rivet a patch, seam sealer the hell out of it and bondo it over. But it would be too tough on an edge like that because of the overlap.
There's always panel bond. Cut a nice patch, form the edge, use a flange tool and recess the patch in. Glue it in. Finish off with a little filler prime and paint. 1000 times better than a kitty hair newspaper *** patch
Go to harbor freight and get there cheap little mig and start practicing on some s**** metal my buddy still uses flux core for all his body work and as long as you clean all the slag off you can get good results Iactually welded lower fender patches on an o.t. truck with it because I accidentally pinched my gun liner of my welder in the door of my truck still looks good 3 years later. You can get a used might on craigslist for like 100-150 bucks all day long or get the coupon and go get a cheap from harbor freight there fine to learn with. I'd personally rather cut the rust out and leave a hole then fill with bondo. Bondo should just be used to skim and even out the surface.
Pulled the carpet and stuck a mirror back there and there is a patch already there. I ll have to grind it back to see what i really have. Meanwhile i started on the other bad spot and found this. I guess if these two spots are the worst im not doing to bad.
If this will be your 2nd home paint job, IMHO, you should step up and buy some used welding equipment. The money you save from not having to pay to have the metal work (welding) properly done will quickly pay for your new tools. Anything short of cutting out all the cancer and welding in new steel will be second rate work. Unless you don't have a desire to improve your skills and workmanship quality with each new build you tackle? This may be a good vehicle to start practicing on.
31. . ., I like panel bond way better then a riveted patch. Not saying anything against riveted patch guys, I have done it myself. What happens with rivets is that they loosen up with time then your problem is worse then before. Some new cars come with bonded panels and hold up real well.
Anyone tried this stuff from eastwood ? Results? http://www.eastwood.com/no-weld-hole-repair-kit.html
Im working on this now . Yes thats expanding foamthat had bondo over it. It did last almost 4 years though.
'That looks slick however the rear side of metal should be prepped and stripped to bare metal for a good adhesion. There is also pre-resin fibregl*** patches which could be used in a similar fashion but again the backside of metal needs prepped. I still weld all holes regardless of size.
The Jalopy Journal
