First Try At Rust Repair (pics)

[fatlife]

I did this awhile back and was looking through my pics and was quite proud at the job i did and thought I would post it. 3 years ago when I used to get to drive the car there was always some rust in the far corner right below the windshield on the dash. I knew it was there but never knew just how bad it was until lately when I pulled the windshield. what I thought was a small rust hole was a huge area of rust that went 2 layers deep. So I cut out what I had too and this is what I had(area is brown due to rust treatment, it cleans up to bare metal)

so after cutting the metal I took posterboard and started cutting out shapes, and basically made metal orogamy. I had to fill in both layers of metal as there is a upper dash and lower dash and the rust went through both of them.

So I finished welding all the bits and pieces in and ground it all down smooth. It took some time as there were a lot of sections of really thin metal and I had to be carefull as not to burn through. After welding and grinding(you can't see the first layer because its covered by the second) I sprayed it with some self etching primer. the first layer was sprayed with weldthru so it won't rust again later

After this was done, I used a light coat of filler to smooth it all out, and then put a few coats of high build primer over it all, sanded that down and then hit the entire dash with a coat of semi-flat black paint. Looks great!


Now I need a new dash pad and a new paint job for the entire car!