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1989 Pontiac Formula Rust Repair - Corrosion Cure

Rust Metal
Welding rusted metal is a... 
   
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Rust Metal
Welding rusted metal is a miserable job, and doesn't make sense when you are trying to get rid of rust, so don't be shy and cut at least a half inch into good steel to avoid chasing an ugly weld into rusty metal later.
Rust Part
Another hammer formed part... 
   
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Rust Part
Another hammer formed part is used to duplicate the original geometry.
Rust Butt Weld
Due to the geometry, a combination... 
   
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Rust Butt Weld
Due to the geometry, a combination of lap, butt, and plug welds are used here. A coat of self-etching primer and paint will take care of the interior.
Rust Corner Cut
Rust Large Piece
Trying to close the hole with... 
   
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Rust Large Piece
Trying to close the hole with one big piece was probably a bit ambitious, as I ended up have to hammer several features and bends into the part; cutting into two smaller parts would have made the job go easier.
Rust Corner Part
The hinge support structure... 
   
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Rust Corner Part
The hinge support structure is replaced with 16-gauge steel, just as original.
Rust Corner Clamps
This part was made before... 
   
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Rust Corner Clamps
This part was made before I discovered shrinkers and stretchers--and it suffers for it, but is still a structurally sound fix.
Rust Smaller
Again, breaking the puzzle... 
   
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Rust Smaller
Again, breaking the puzzle into smaller parts.
Rust Ribbed
Closing up the rocker panel... 
   
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Rust Ribbed
Closing up the rocker panel I attempted to add a couple of ribbed features like the factory had done using basic hammer forming techniques.
Rust Corner Finished
After fitting the fender back... 
   
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Rust Corner Finished
After fitting the fender back on, a hole will be added with a corresponding nut welded to it to duplicate the factory fender mounting.

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