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Re: Build dilemma
Are you actually cutting out the rusted panels and butt welding them back in, or are you overlapping and welding the panels on? You really don't want to overlap them in that area. Every time it gets wet water is going to get into the "seam" between your panels and rust it out all over again. I would butt weld everything and when done use a garden type sprayer and coat everything with a thinned out rust encapsulator, por 15, or similar product. Overlapping the heater box area is fine, but you don't want to do that for the two corner cowl patches.
You're doing fine. Butt welding isn't difficult, it's the same as you're doing now, it just takes a little more time to "fit" the panels, leave a thin gap, then weld them together.
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