this is becoming one of those "I'm not going to search, coz I'm sure no one has posted about it before" topics
http://s29.photobucket.com/albums/c292/arowland2/rust/
before i started
http://s29.photobucket.com/albums/c292/aro...rust%20repairs/
after i finished
what you do:
1: get angle grinder, grind away all patches of rust and cut out the holy sections (sunday sections) :S
2: get a sheet of decent but not too thick steel. a few different thicknesses depending on the job helps. (in the rear window corners i used 3mm galv steel. other sections 1.5 mm galv steel and others computer or other white good cases.
3: cut steel to approximate shape (i used a bandsaw) and then bash with a hammer to resemble the shape it should, either clamp or rivet in place. (i always clamped mine)
4) weld it in
5) grind it back so nothing sits above the level it should (hammers are helpful)
6) treat it with an anti rusting substance ( i used a product called penetrol, its great, been almost 18 months, nothing has come back that i treated with the stuff)
7) bog bog bog til your hearts content
8) sand sand sand til there is no skin left on your fingers
9) repeat steps 7 and 8 for many months
10) it must be right now, prob gettin close
11) now its time to sand the whole car back (orbital sander ftw)
12) primer, and sand, primer and contrast coat and sand, primer and contrast coat and sand, primer and contrast coat and sand, primer and contrast coat and sand (ALWAYS sand using a block at this stage, so that you remove all the valleys and peaks that appear in old metal) the contrast coat shows you the low and high spots (for the contrast i used a tin of red export spray paint) p.s if youve gone to the effort of doing a good job with the rust repairs don't f@$k out on the making it straight stage. as tedious and irritating as it is :D
13) many months later you will have a car that is straight
14) now spray it and clear it and sand and polish
15) go for a spin and try not to crash into a pole :S
hmm i think thats the basics
any questions?
oh, for the record, i did not use any panels off other cars
even the spare tyre well i welded plates into and bogged up (its so f@$kin shit in there tho, tyre sits about a cm taller than it should. maybe it would be a good idea if your tyre well is rusted out to get a replacement one. i have a rust free one if you need.. but as you havnt PUT YOUR LOCATION IN YOUR PROFILE i can't tell whether its any good to you ;)
hope ive helped
anyone, feel free to correct me