As promised, I am posting some tips for repairing rust holes
with a mig welder. However, since this is a complex subject, I
decided to write this up as an article so that I can cover several
aspects of rust repair. As such, I will be posting this article
in 3 parts plus this intro over the next several days. The 3 parts
are - Part 1) Rust : How to deal with it,
Part 2) Repairing small holes
Part 3) Using patch panels
First off, I would like to make a few disclaimers. I am not a
professional welder, nor a professional auto restorer. I am an
enthusiast who has performed restorations and rust repairs on
several cars, mostly my own. Of these projects, the most
difficult (by far) was my '54 Chevy pickup truck, which required
replacing the inner and outer cowl panels and cowl brace on both
sides, the lower firewall, floorpan on both sides, and the lower
rear cab corners. This project and the others has taught me a lot
about repairing rust holes. The techniques required for rust
repairs are different than for joining 2 pieces of new metal, and
it is these techniques I will be covering over the next several
days.
Next, realize that there is more than 1 correct way to do most
anything, and this is no different. The methods listed are ones
which I have used successfully in the past. However, these
methods should be considered as opinions, as "your results may
vary". Also, these methods are in some cases more time consuming
than what a commercial body shop or welder would do, as these
shops will usually choose the easiest method which gives
satisfactory results.
Also, recognize that welding is inherently dangerous since
there are fire hazards, burn hazards, and electrocution hazards
when using a welder, so safety must always be kept in mind. I
can't assume any liability for any advice or suggestions given
herein, so use caution.
Finally, I welcome comments and suggestions (no flames
please), since sharing information is what this is all about. You
are also welcome to use this aritcle for club newsletters, etc
provided that it is a non-profit publication, the article is
properly attributed, and that I get a copy. If you post a
question to me, please be patient, as I come to you on a delayed
basis (1 - 2 days).
Now with all the administrative details squared away, you can
look forward to Part 1 - Rust: How to deal with it, which should
post tommorrow.
Cheers,
Mike Harlan
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