I finally got back to work on my Conestoga after a break to change spindles on my red car and take a couple trips. This project was repairing the rusted front passenger side body corner. Here are a few pictures taken during the process. More details can be scene following the link in my signature. I will preface by saying that I had never done anything like this before, so feeling my way along with advice from more knowledgeable folks. I am developing my welding skills too and usually weld for 5 minutes then grind for 10. I am confident in the structural integrity of my repair, but also glad it will be hidden when I am done, LOL.
Here is the rust damage as found
First I cut away the rusted metal
I then formed a curved piece to match the contour of the outer edge and welded it in place, then cut and bent a piece to fill the flat portion.
Here is the repair, close to finished. After welding the curved piece in place, I then spot welded the bent portion and stitch welded the inside corner along the curve and the top and bottom edges. Then I cut the excess curved pice off with a cutoff wheel and used a grinder to remove the remaining excess metal.
And finally painted with self etching primer. It will eventually get painted when I do the firewall and door jams.
Next project is the drivers side floor.
Here is the rust damage as found
First I cut away the rusted metal
I then formed a curved piece to match the contour of the outer edge and welded it in place, then cut and bent a piece to fill the flat portion.
Here is the repair, close to finished. After welding the curved piece in place, I then spot welded the bent portion and stitch welded the inside corner along the curve and the top and bottom edges. Then I cut the excess curved pice off with a cutoff wheel and used a grinder to remove the remaining excess metal.
And finally painted with self etching primer. It will eventually get painted when I do the firewall and door jams.
Next project is the drivers side floor.
BP
We've got to quit saying, 
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