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spiff's Avatar
 
Join Date: Aug 2005
Location: Markham, Ontario
Posts: 219
Need advice on how to fix rust on rocker/jamb

So I'm busy fitting new fiberglass bumpers and rockers to my car to get ready for paint, but there's also some rust that has to be addressed. Most of it is surface stuff that can be cleaned up and POR-15'd, but there is one hole pictured below that I need to get fixed properly.



I sent Dave at TRE these pics and he cut out a section from a clean car that is definitely bigger than this and sent it to me. The piece he sent includes the jack tube and extends well past both ends of where the rust starts and ends.

My question is:
What is the best way to repair? Is it sufficient to cut out the surface metal and replace (weld in) or do I need to replace the metal inside? I'll be having a shop do this.
Does the shop need to be very familiar with 911's to do this repair or can I take it to someone that just knows how to do bodywork/rust repair well?

It seems fairly limited to this area as I believe there was some dirt that was trapped in the end of the rubber threshold that just trapped moisture over time and just started to rot away.

Any suggestions for shops in Toronto?
Thanks in advance!

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Old 03-21-2006, 07:14 PM
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jpnovak's Avatar
 
Join Date: Apr 2000
Location: Austin, TX
Posts: 9,108
Here was my repair.

Rust repair: lower latch panel.

btw, if you are having a shop do it... Find a shop that is familiar with cutting and welding panels. If you already have a patch section it is not difficult to fit a part of the cut-out. btw, if you have a large chunk, be aware that there are 4 panels that come together not counting the jack tube and its support. These are all leaded from the factory. All the lead must be removed prior to welding.
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Old 03-21-2006, 07:28 PM
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Join Date: Jan 2004
Location: Seattle, WA
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Here's how I'm doing it:





All done with off-the-shelf pressings from Restoration Design and Dansk.

Old 03-21-2006, 09:09 PM
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