Inner fender rust- how to fix?

[bkelly]

I've started to paint everything not seen with Eastwoods Rust Encapsulator. The underside of the rear hatch is done and looks great. Today I started on the front inner fender area, skipping the floor pans which need to be cut out still. On the passengers side there was a bubble of rust. I'm using a polisher with a wire cup to remove any scale and when I pressed against it, it went right through. There is about a silver dollar size hole. This obviously needs to be cut out. My question is, what's behind that panel? Since it's rusted through, I don't think the inside will look pretty either.

What I'm planning on doing is cutting the panel out, sand blasting any rust behind the panel, and welding a patch panel over it. I've always wanted to try to weld and this is a good spot to play around with out having to make things look that good since it's not seen.

[EScanlon]

At that part of the car, that's the outside of the upper forward corner of the kick panel.

If you look up from the passenger floor, you'll see the elbow of that rubber tube you have in your picture that connects to the cowl drain. You'll see light through the hole you've opened up. It's just starting to creep into the fresh air duct.

You'll have to remove most everything from that area to cut out and reweld there. Thankfully it's a flat piece of sheet metal., so it isn't impossible to fashion a patch.

FWIW

E

[webdawg1]

You'll probably find a lot more RUST the more you dig...You'll be digging into the bottom of the right side cowl area...could be a real mess once you get in there...Let us know what you find...

webdawg1

[Bart Hoedemaker]

Jep, you will be scared, everything rusty.