Originally Posted by bigdog7373
Id cut the the rust out in shapes that are easy to work with, even if that means you take some good metal with it. It's much easier to cut out a rectangle and weld it in place than it is to have curves and circles and stuff.
I agree that its easier to cut, but when welding it can make it more difficult in the corners because of heat build up causing more distortion.
An accurately positioned patch panel, a metal scribe, and set of quality tin snips should give exellent results on most shapes.