Sarge's rattle-can rebuild

[68Timber]

Here's my two surprises hidden behind the windshield gasket. I bought some 16 gauge steel from Home Depot today to cut some patches out of. I haven't welded anything that thin yet, hope I don't make a mess of it. This is a bad area to have to cut the rust out of, can't get the cut off wheel in on both angles. I've got some bits for the die grinder that may work.

[MTCK]

That repaired section looks darn good! My experience with filler is the same: goes everywhere but on the low spot. Good thing that tree fell so you can get that all tuned up right. Nobody likes surprises...

[Front Range]

If you don't have one already there are body files to shave the filler down before it completely sets. Makes shaping a bit easier.

[68Timber]

Originally Posted by MTCK

That repaired section looks darn good! My experience with filler is the same: goes everywhere but on the low spot. Good thing that tree fell so you can get that all tuned up right. Nobody likes surprises...

Thanks! Yeah, that's what I was thinking. I'd rather be driving it than working on it, but if it's got issues better to know sooner than when they get worse.

Originally Posted by Front Range

If you don't have one already there are body files to shave the filler down before it completely sets. Makes shaping a bit easier.

I went to an auto body supply store Friday and told the guy what I was working on, and that I'd never worked bondo before. It'd been nice if he'd mentioned those. It worked out OK though.

[68Timber]

Getting close. I picked up a small piece of 16 gauge steel from Home Depot to cut some patches out of. I was guessing the size needed and it turned out to be thicker than the damaged area. I used it anyway, can't see what it'd hurt. It probably kept me from blowing through more times than I did. Passenger side a-pillar first. It has one hold I need to tack.

[68Timber]

This other area is in the drivers side cowl area. Is it just me, or does this rust hole look like a face that's laughing? Rust removed, patch cut, then tacked in. I think I was holding the trigger too long. It was late yesterday when I did this one and when I ground these smooth and went to make another pass around I blew through twice. I don't like chasing mistakes when I'm tired so I put my toys up for the day. I'll get back after it today and hopefully finish the repairs and prime/paint.

[Front Range]

Nice job, one less worry.