Originally Posted by Vic1947 (Post 7142213)

I recommend a product called Gem Rust Killer. It's phosphoric acid with some wetting agents and extenders added. I use a spray bottle to apply it until the surface is wet. It converts the rust to iron phosphate and turns it black. If you don't plan to paint the surface, just let it dry. If you plan to paint over it, you can rinse the area with water after all the rust has converted (turned black) and pat it dry with a towel. Then let it air dry completely before painting. It's the same consistency as water, so it easily seeps into the seams. You may need to spritz heavily rusted areas several times and let them soak. If you want to give it a try, you can look it up on the Google. The folks that make it are in Houston, TX and sell direct. Just give them a call.

As far as the welding is concerned, fumes are always a problem. A respirator is the best way to keep out the bad stuff. They can be a pain, but most helmets have enough room to accommodate one. I never weld galvanized without wearing one. Your lungs will appreciate the love later in life.

Originally Posted by swamp rat (Post 7142443)

Big time feels like lets get nervous time LOL! Yea the inner is fine except the lower flange, nice and solid. I don't think there is seam sealer in the fold over seam on the door, least i didn't see any.

Originally Posted by swamp rat (Post 7142517)

Below is a link to the respirator filters i have, good for acid vapors ect, not sure what kind of gas vapors welding creates or what might be created if i weld over any chemicals like Phosphoric acid ect. Do you think i should be good?

Originally Posted by Vic1947 (Post 7142956)

If it turns into a goat rodeo

Originally Posted by Vic1947 (Post 7142956)

This filter would work just fine for you. Phosphoric acid reacts with iron oxide to form iron phosphate which is essentially inert. I don't think there would be much of an elevated danger when welding thru it. That said, your respirator is approved for chemical processing and exposure to several noxious substances so it's a good safety measure to use it when working around vapor irritants.

Your patch is going to be tricky but if you go slow and keep the heat down, it's do-able. If it turns into a goat rodeo, you can always skin it like DWilbur suggested. Keep up the good work!

Originally Posted by ryanroo (Post 7143000)

:lol:

If you have any question, wear the respirator. Welding heat will vaporize alot of things, some don't really bother. The arc can have an odd effect on stuff and the uv can spice stuff up too. Best to be safe. I do a lot of breath holding when I weld.

Good luck with the repair!

Originally Posted by DWilbur (Post 7142871)

It might be easer to replace the door skin and the left inner bottom corner with new panel patches. Then you can media blast the rust inside the door paint to preserve the rest.

Originally Posted by 0311Chevy8152 (Post 7146153)

I'm following along. Unfortunately I can only offer moral and not technical support. But I like what ya doin and keep up the good work!

Originally Posted by swamp rat (Post 7156775)

The compressor repair guy is suppose to be out Tues or Weds.

Originally Posted by Vic1947 (Post 7156868)

I'm assuming Quincy will cover it under warranty. Still, it sucks after all the research you did plus the $$$.

As for the cleanup, I use solvent for messes like this. The stuff I buy is hard to find (Hangsterfer's Ozonic 117) but any Varsol type product would work equally well. You can also get Wax and Grease remover from most places that sell paint and body supplies. Usually available in quarts or gallons.

For homemade wax and grease remover, mix one third isopropyl alcohol, one third acetone and one third water. Works great and the components are readily available.

Originally Posted by 7dee2 (Post 7158033)

That is not good news on the compressor, but like most new things a little tweak/repair and it'll be good to go for a long time. Pressure gauge biffed it on our new compressor immediately. Couldn't wait for the replacement to get here so now I've got a spare.

Your rust repair work is progressing very nicely, keep up the good work!