22 Aug 11 10:39, mark lewis wrote to Mark Hofmann:   
      
      
    MH>> I was wondering what the best process was for fixing rust issues?   
      
    MH>> My experience has always been you had to cut out the effected area   
    MH>> and then use body filler to fix the area.   
      
    ml> cut out the area and then weld/braze in a new piece... then grind and   
    ml> smooth the seam... finally, proper priming and painting ;)   
      
   You should make a template of the area being cutout, so you know how far   
   to cut, by marking a line on the rusted area, around template. If you're   
   using a MIG welder, don't weld it on with one continuous bead, use a   
   stitch weld so you don't warp the sheet metal.   
      
    MH>> I have one spot (about 2 inches by 2 inches) right near by rear   
    MH>> wheel area on the driver's side that has had this rust area under   
    MH>> the paint that has slowly expanded.   
      
    MH>> I am considering cutting it out, but want to know the best way to   
    MH>> repair.   
      
    ml> i guess this depends on what you really want... i'm rather spoiled   
    ml> from watching the TV shows where they go and swipe someone's old   
    ml> vehicle (with help from a family insider) and a week later they   
    ml> present a completely rebuilt vehicle... there were, at one time,   
    ml> three of them on the air... these days, chip foose's Overhaulin' is   
    ml> all i can find...   
      
    ml> i remember when i found out that chip used to work with Boyd   
    ml> Coddington who had the show American Hot Rod... many customizers in   
    ml> the auto industry started with boyd... we lost a good man in 2008   
    ml> when boyd died of complications after surgery...   
      
    ml> anyway, in both of these shows, when they were fixing rust areas,   
    ml> they cut out all the bad metal and welded or brazed in a new piece   
    ml> and then worked the area so that it was undetectable from the outside   
    ml> when completely finished...   
      
   I didn't know Boyd had passed. That was a good show, even though Boyd   
   didn't do any of the work, just the bitchin'...   
      
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