body repair help in window area

[73Manta72gt]

Any advice on the best way to repair? I have a flux core welder and a pop-rivit gun. This will be a daily-driver not a show car, but I don't want a water leak

Thanks

[azopelnut]

I can only guess that the rust occured because the rubber moulding failed. You can use POR-15, fiberglass or bondo for a temporary fix but the rubber moulding needs to keep the metal dry so the rusting process is slowed down

[guyopel]

Cut out the rust area and weld in a replacement piece .
I suspect you will find more damage after you remove this section . HTH Good luck
John

[trlmr]

You will need a tool to cut out the old metal. The only tool that really works good for what you need to do is a die grinder with a cut off wheel. They take quite a bit of air, but you can use a small air compressor if you aren't in a big hurry. I never could get flux core wire to work very good,( too much splatter) but maybe you will have better luck. You are going to have to weld metal back in after you get rid of the cancer. I don't see how bondo or epoxy would fill a hole that size and last for any time at all. Perhaps if you don't want to weld it you could use fiberglass cloth and resin then fill the rough with bondo. Try to leave the curved part of the metal if it is possible when you cut the rust out-it will make the finish work easier. It isn't that hard to do, just don't expect perfection if this is your first repair.

[73Manta72gt]

Some pics of the repair. I burned through the sheet metal on the car 5 or 6 times. I used JB weld putty and bondo to smooth things up a bit.

[markandson]

Some pics off the repair. I burned through the sheet metal on the car 5 or 6 times. I used JB weld putty and bondo to smooth things up a bit.

Not bad considering what you started with, the real test will be that of time to see if you have paint problems or leaks in the future.

[73Manta72gt]

If I had to do the same job over I think brazing would be a better option than welding. The body on the car is really bad not worth the effort to restore, but it gets good mpg and is fun to drive.

[Ooooner]

Hey Helmut, I've seen that car.. It's not near as bad as you say it is! Go for the restore!

[opelspyder]

Alot of times people think because it is a driver you can get away with half way repairs. These areas matter on any car driven or showed, they have to be fixed right, or to the point where rust will not forn anymore. What you did looks fine, and will be covered by the gasket as well. Don't shortcut repairs, because it is a driver, sometimes it has to be better than show to last longer
Keith