Hey guys I there are some nasty rust holes in the sills of my ED wagon and am looking at cutting them out and replacing them. It's beyond the point of just surface rust and the holes are pretty goddamn deep. there are some average size ones near the rear that seem pretty straight forward but at the front near the front door it's creeping up into the cabin. I've never done anything like this before but I have used angle grinders etc so I have some idea of how to just cut out the affected areas. Basically I'm guessing it goes something like -

Measure out area to be cut out
Cut out area and grind area around edge to be welded
Test new replacement/patch panel and clamp in
Tack weld into place
Weld in
Grind welds smooth
Seal or rust treat bare metal
Bog/fill to smooth finished area
Prepare for paint?

That's my idea. I have literally no idea if that's correct at all. I have a limited knowledge of welding as you can see haha, any help would be greatly appreciated

 

 

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yeah somethin like that .... altho 1st probably be - cut hole...inspect .... cut bigger hole.....cut a bigger hole .... lol

have an EA sedan with minor rust & a EB sedan with rust in the sills ... & who knows where else