I'm on my last body panel and of course run into unexpected issues.  Rust has infiltrated between the hatch skin and the 'doubler' shown in the picture.  The result is some pinholes in the outer skin, and a lot of swelling between the two pieces of steel.  This piece clearly had to come out.

Question is what to do now.  I think replacing the piece and joining it with body adhesive is probably the way to go.  Any suggestions as to what material can be used between these two pieces of steel that will keep water and rust out?  Or any other suggestions on how to repair this area?  

Thanks in advance.

 

I would make a new doubler

Treat the rust inside the hatch

Prime both then install with panel adhesive

Make sure you get it pulled tight enough that the lock will go in with the keeper!

Any squeeze out through the pin holes can be dressed down and filled over