Advice..... Again

[WHITE WHULF]

I`m in the process of repairing a few minor probs with the 90 before I get ready to paint, one of these job is to repair the bulkhead, thats right, its a 90 and the bulkhead has rusted (pretty badly) in the top corner. I`ve ordered a couple of bulkhead repair panels from paddock (too much expense and inconvenience to replace the entire bulkhead at the minute, so here`s the problem, do you need to cut out the area the same shape as the repair panel and weld it into the gap, or do you just weld the panel over the top?

[Sooty]

My advice (and I an no expert) is to mack sure you get all of the rusty metal cut out as rust is like dry rot the smallest bit left and it soon starts to grow and you need to weld to good metal or you are never going to get the strength you need.
Also when you are finished you cannot put too much paint on to seal the job from the dreaded water and salt.
That is my 2 peneth for what it is worth.

[cstokes]

When i do any repairs like this i always cut out the rusty metal, and sometimes i cut the new panel to fit the area cut out this way when it is welded in it will sit flush with the existing panel work. If you simply weld the new panel over the top the rust underneath will soon start eating into the new panel, also it will sit proud of the rest of the body work and look unsightly. It can also lead to things not shutting properly like the bonnet may catch the new panel. Hope this helps.