Rust repair strategy???

[bill..g]

OK, i need some guidance.  I am working on rust repair on what will be a daily driver; no aspirations to show the car but as long as i am doing this, i don't want to do it in such a way that it will be unsafe, unsightly or risk having to do it again in my lifetime (lets figure 20 years).  That said, i have three areas of rust in the driver rocker, one at the front above the jack support and two at the mid door.  Each is no more than 4" wide and the back two are about 4" apart.  i have a replacement sill to work with but have never really welded sheet metal and am intimidated.  So, would you suggest patching this damage as 1 piece, 2 (patching the rear 2 areas with one patch) or 3 (minimizing the area of patched metal)?  How far vertically would you go?  The back two holes are well below the molding mount holes so could easily hide that seam behind the trim.  The horizontal area of the door opening is all in good shape so i think no reason to expose the joint to open examination. 

 

Also, given the location of the repair and the intended use of the car, would you suggesting butt welding these patches in  or would lap welding suffice?  

 

The area between the inner and outer sill have surface rust but it does not appear too deep.  Would you address with by applying POR 15 or ?.  I am thinking something should be done while the area is somewhat accessible, just not sure what.  

 

Thanks in advance for any input you would care to provide.  

[TobyB]

Quote

 risk having to do it again in my lifetime 

Get a replacement first,

then take the rocker off.

 

There's too much rust in there to just patch it, if you want it to last 20 years-

and anyway, it feels better to do it right!  And honestly, at this point, it's no

harder and will be a lot better.  You'll be able to clean and seal the inner

sill panel, and it'll all be done for good.

 

You will find if you try to patch that the metal surrounding the holes is just too oxidized to weld a patch to...

 

Sorry, 

 

t

 

[EvilEmpire]

We are in the middle of the same type of repair. We cut out just what needed to be repaired. Had to rebuild the inner rocker with some flat stock. We got the replacement panel and cut that panel to make the patch.

Welded on the jack point with some flat stock. Using flange tool to put the patch panel under the top seam so it fits tight. Punch holes on bottom to spot weld to lower side. TiG weld the seams. Some pictures

[bill..g]

Thanks Toby and Evil for your input.  One question, Evil: why TIG on the seams?  Could the same be done stitch welding with a MIG machine?  

[EvilEmpire]

You can do MIG - got my son the welder a new TIG machine and he likes using it. 

[bill..g]

Oh, what i wouldn't give for a son who can weld!!!  Alas, mine is 12 and neither of his sisters seems to show any promise whatsoever... ;-)

[bill..g]

Oh and a belated happy fathers' day...

[Simeon]

1 hour ago, bill..g said:

Oh, what i wouldn't give for a son who can weld!!!  Alas, mine is 12 and neither of his sisters seems to show any promise whatsoever... ;-)

 

You just need to be tougher. "No dinner until Daddy sees some quality welds" they'll soon be laying down stacks of dimes for you. 

[EvilEmpire]

Son completed welding this morning. Grind and finish to do.