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Old 12-04-2005, 07:18 PM
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Cutting out sail panel rust....

I dug out an area on the drivers side sail panel of my 69 Camaro that was filled with Metal 2 Metal, underneath are a few rust holes and some pitting. What would be the best way to repair this besides new quarter? I thougt about cutting around the section untill I got to good metal then weld some 16g? sheetmetal in. Is it a bad idea to cut on the sail panel, I plan on staying away from the lead seam.

Heres some pics -
http://i7.photobucket.com/albums/y26...DVC00249-1.jpg
http://i7.photobucket.com/albums/y26...DVC00253-1.jpg
http://i7.photobucket.com/albums/y26...DVC00251-1.jpg

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Old 12-04-2005, 07:27 PM
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The pics above work.....please delete my first post
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Old 12-04-2005, 08:18 PM
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Yeah, cut out the bad area and replace it with some new metal, 18 or 20 guage would be plenty thick enough, 16 guage is way overkill and harder to work with. Remove any remaining surface rust with a 3M clean and strip disc followed by naval jelly scubbing with a red scotchbrite to remove the rust from any remaining pits. Look up Randy Ferguson's post on rust removal for the low down on how to get all that rust off with naval jelly. Peek up inside the quarter panel with a mirror if need be and look over the interior of that area to make sure the rust isn't severe on the inside. When all the rust on the outside is gone then apply two coats of epoxy primer and the filler of your choice. Notice how the rust migrated under the allmetal filler that was there, if there would have been epoxy under it that never would have happened. Treat the backside of your repair with POR15, Rustoleum, or just a good cavity wax type spray like 3M's rustfighter or Transtar Amber coating. If you don't protect the backside of the repair it will start rusting at your welds, etc. Bob
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