Patch panel welding - body guys
Cut it square and flange the new piece with a flange tool. You want to tuck the new piece behind the original panel. The 1st reason is it is easier to flange the corners to the corner. The 2nd reason is? After completing the welds you can spray a rust paint such as "Chassis Saver" first choice "POR15" second choice. or "Rustolem" 3rd. Flanging the new part and tucking it behind the the original lets the material gravity flow behind the seam and seal it. I have learned over doing many over time that if you don't seal that seam completely it will rust twice as fast. I do this with all patch and quarters I install.
I did a patch on one side of this almost rust free Duster because it had a very small hole. I cut the complete bottom off and reversed flanged it because I would be able to seal it and let it gravity fill. If you look close you may be able to see it in this picture about 1 inch below the marker. The seam goes the complete length. I left it a little lower then the trunk extension to hide the seam. This car after I filled the quarters and the rockers is almost guaranteed to never rust again.
It is funny you started this thread because I am about to do the same thing to my 05. These trucks rust because the quarters are foam glued to the wheel house and they hold moisture. I have two 05's and my single wheel is on its second rust free bed. This time I am fixing it right. Original rust free beds will rust. Ask me how I know. I will pinpoint spray a rust paint and load it full through the taillight opening until it runs out the bottom
Cut it square and flange the new piece with a flange tool. You want to tuck the new piece behind the original panel. The 1st reason is it is easier to flange the corners to the corner. The 2nd reason is? After completing the welds you can spray a rust paint such as "Chassis Saver" first choice "POR15" second choice. or "Rustolem" 3rd. Flanging the new part and tucking it behind the the original lets the material gravity flow behind the seam and seal it. I have learned over doing many over time that if you don't seal that seam completely it will rust twice as fast. I do this with all patch and quarters I install.
I did a patch on one side of this almost rust free Duster because it had a very small hole. I cut the complete bottom off and reversed flanged it because I would be able to seal it and let it gravity fill. If you look close you may be able to see it in this picture about 1 inch below the marker. The seam goes the complete length. I left it a little lower then the trunk extension to hide the seam. This car after I filled the quarters and the rockers is almost guaranteed to never rust again.
It is funny you started this thread because I am about to do the same thing to my 05. These trucks rust because the quarters are foam glued to the wheel house and they hold moisture. I have two 05's and my single wheel is on its second rust free bed. This time I am fixing it right. Original rust free beds will rust. Ask me how I know. I will pinpoint spray a rust paint and load it full through the taillight opening until it runs out the bottom