Rust repair advice

[ShinyC10]

So the rust has been here for a year or so but just haven't really gotten the courage to cut into my truck but it's getting worse sooooooo I plan on diving in during Christmas break. It's the typical rust in the cab corners, door jams, bottom of the door and around the windshield channel. Can't seem to upload pictures though

[ShinyC10]

Got it!

[ShinyC10]

It's like this on both sides

[Barbecue]

I've often found that vehicular rust is like an iceberg - what's visible is only a portion of the issue. I recently had the rust taken care of on my '86, here are a couple of pictures from that process. It is hard to tell from the picture, but new metal was required all around the windshield, bottoms of the doors, cab corners...

[ShinyC10]

Did you purchase those patch panels off the Internet or what?

[Barbecue]

Originally Posted by ShinyC10

Did you purchase those patch panels off the Internet or what?

Nope, patch panels made from scratch. Whenever I do rust work, I try to make as clean a hole as possible (cut at least 1" back from the ragged, rusty edge) then make templates with thin cardboard, like a cereal box. I trial and error fit the cardboard many times until it is perfect, then trace onto new sheet metal following the template exactly.

BBQ