Have I told you all I suck at bodywork?
Well, I'm learning, but damn, it's hard to get good results.
@eldubb440 : You have nothing to fear from me my friend!
OK, so I ended up with this hole after I cut out rust in the inner wheel well (left rear wheel):
Ouch. OK, so I started to cut panels to repair it. There were multiple patch pieces needed, including the floor, inner and outer wheelhouse, and rocker. I decided I was not going to butt weld this since I would be lucky to even remotely be able to create pieces to fix this. It is impossible to see from the picture, but multiple bends in multiple planes are needed to patch this. Certainly not an easy fix for me, a total beginner with this stuff.
So I started out and cut a piece for the floor, then I welded it in using plug welds.
It is really hard to hold the welder and weld in tight places, and getting a good ground was hard too. As I went along, I discovered how critical it was to have CLEAN metal where it was being welded AS WELL as for the ground lead. Another issue is blowing a hole through the metal while welding. Sometimes it is OK, and then suddenly a dime sized hole gets blown out of no where! Crap!
This put a patch in for the floor, but much more was needed (not shown is that I also needed to weld a repair to the seat belt bolt too).
Unfortunately I didn't take many pictures of the remaining pieces that I made. I made 4 additional pieces of metal that I welded in. I think if I was grading myself, I was heading for a D- if I was being kind. But then suddenly the pieces just started falling together and the result (so far) actually is at least passable. Well, you be the judge...
Here is where I am at for now - I actually got the pieces to fit OK! I still have more spot welding to do to fill in areas where there is no weld yet (you may notice there is some plug welding as well as edge welding). After that, then the usual grinding to smooth out the welds.
Now I know for many of you this would be an easy job, and you likely would have done a MUCH better job than I did, but I dove in and I am learning! (Some by the school of hard knocks too!)
Hopefully, once the welding, grinding and heavy coat of undercoating is done, it will look pretty decent. At least there won't be a big hole there!
RoadKill at its finest!
Hawk