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Rust Filler Neck

Butt-welding the patch panels has allowed me to very closely mimic the original geometry. It's tempting to keep grinding until the weld disappears, but likely you will grind through a good deal of sheet metal before the weld is completely gone, so resist the temptation and throw a skim coat of filler down before you paint if the repair must disappear.To the right of the image is the opening where the fuel tank filler neck pokes through. Notice I duplicated the flange around the opening--this is an easily overlooked detail, but it was fun to create and goes a long way to making the repair disappear back into the car.
1989 Pontiac Formula - Corrosion Cure

 Butt-welding the patch panels has allowed me to very closely mimic the original geometry. It's tempting to keep grinding until the weld disappears, but likely you will grind through a good deal of sheet metal before the weld is completely gone, so resist the temptation and throw a skim coat of filler down before you paint if the repair must disappear.To the right of the image is the opening where the fuel tank filler neck pokes through. Notice I duplicated the flange around the opening--this is an easily overlooked detail, but it was fun to create and goes a long way to making the repair disappear back into the car.  View Related Article

 

 

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