On the proces of geting my project 95 ready for paint, I found some rust as most of us have. Ive seen a bunch of people asking how to fix rust, so I will be taking pics as I go & show you guys how I fix the problem. If you have tools to bend & reshape metal, & a welder, that would be the way to go. But since I dont have the equipment I will be fixing the holes with fiberglas.

The stuff that is needed for this is:
fiberglass resin & the fiberglass cloth
bondo
primer
rust neutralizer (POR-15)
sand paper
a dremel
& multipurpose panel adjesive by SEM (abvailable at the paint suply store & if you do any kind of custm work to your car then is a must on your toolbox)


This is the rust that I have. It wasnt visible with the trim on, but when I removed it & started poking at it, this came out:


first step is to deside how much needs to come out. I took about 1/2 inch extra around the rotted part.


look at all the rusted crap that is acumulated there. I cleaned it out with a clothe hanger & a vacume.


Then grind out to rust with the dremel. Keep on going a little bit further untill you are 100% shure there is no more rust.
& then spray some rust neutralizer, inside & out.


After a couple of hours I cleaned the area, dryed it, & primed it.


Dont leave metal exposed overnight, cause it will rust againg. Tomorow Ill post the progress.

ooh definitely looking forward to this...

all the seams where filled with a orange material that was deteriorated & letting water rust the metal. I got it all out with a metal brush tip on the dremel. Then filled the gaps with the black panel adhesive.


Ok, here comes the fiberglass. I made a mold of both areas with the fiberglass. After it dries & gets hard Ill brake it loose, & will have a exact copy of the area Im working with. (youll see what they are for later)



& I did the same with the metal I took out.


This is the mold I did of the area. I trimed about 1/2 inches over the metal & the same over the hole. This will be cut in to 4 sides & bonded on the inside. It will give me a good strong surface to atach the other pice.


This mold made from the piece of rusted metal will fill the hole & wont rust again.

This looks sweet. I just had to subscribe to this thread. Keep the awesome work coming.

If you weren't such a fiberglass nut, wouldn't you use metal?

Isn't metal the correct way to do body work?

Yes. No offense, but this fiberglass repair is purely cosmetic. It will not restore the strength in that area. Welded metal would be the 'correct' way to repair that. This works well for a cosmetic restoration if you don't have a welder though.

looks good. im a fiberglass fan as well.

If you read from the begeaning, that is the first thing I stated. Metal is the correct way to go, but if you dont have the money to pay, or the tools to doit. Then this would be the 2nd best, & the only other way to permanently remove rust.

Ok, back to topic.
Using the panel adhesive, I glued the fiberglass piece from the back.



Then when it dried, I glued the top piece. then covered the area with the panel adhesive.


After it dries, I sanded it with the dremell. Its hard to sand with a sand paper so the cosmetic sanding will be done after bondo is aplied. This is just to cover the hole & to make shure is strong as the metal.
I added more adhesive to the center where I found some bubble holes.

After some bondo, a lot of sanding, & some primer.