Well, I’m in it now! I started on the passenger side as it’s much worse than the drivers side. A borescope helped me get a better idea of where the rust was. Inspecting through the holes under the rubber door sill was especially helpful.
I ended up cutting a strip rather than cutting straight back to the wheel opening. I’m still not sure this was the best idea but I did it bc the sheet metal I have will cover the entire area. It gives me the option replacing everything I cut out. I also just cut the rusted door jam section at the same time.
All in all, I’m really lucky that the rust stopped where it did. There are so many layers of metal in that area that it could get messy quickly.
I made the cuts with an air saw as it gave me the smallest kerf and it’s easy to control. Other than that the job took a lot of the spot weld drill, air grinder, and air belt sander. That mini air belt sander tool is awesome.
I’ll post a bunch of pics to help anyone in planning this job.
