So I've got a 95 F-150 4x4 that has a little rust right on the edge of the left wheel well. This spot looks no bigger than 3 inches long, and no taller than 1/2''. One tiny spot, smaller than a dime, is sort of pitted, the rest just looks like bubbled paint and maybe surface rust. Any tips on how to go about tackling this? I want to get this fixed quick, as I don't want the rust to spread fast/far. Thanks in advance

 

I'll guarantee that when you sand it down it will be more wide spread than it appears. The only sure fix is cut out the rust and replace with new metal. While there are other fixes like killing the rust, filling and painting, it will be back within a year.

 

Hm, dang, not really what I wanted to hear. This is not good.

 

It's MUCH easier than you might think. If you can weld at all, you can do it with ease, the trick is technique. First, cut as even a shape as you can to remove the rust. Make it easier by cutting (for example) a rectangle, but I find it easier to round the corners slightly. Next, cover the hole with masking tape, then trace the shape of the opening on the masking tape. Once you've done that, remove the tape gently, and lay it on top of sopme sheetmetal about the same thickness as your original part. Cut the outline with a razor blade, then cut out the sheetmetal patch with whatever you have. Snips, cutoff wheel, hacksaw, file or what-have-you, just cut it out as best as you can. Trim it to fit, then clean any paint or rust off both parts and hold it in place with either a magnet or more tape. Next cut a couple of scraps of the same guage metal and practice geting your settings right. If you're using something like a 100v wire-feed, you're all set. They are very easy to do this with, either flux-core or gas welders work just fine for this. The trick is to NOT try to weld a bead. Instead, make a tack, go to the opposite side of the patch, make another tack. Then stop, look it over, hammer it here and there ubntil it fits right and go back to making tacks. Stop every couple tacks and fit it as needed, then repeat tacking until all the tacks touch. Then GENTLY grind it down with a 4" grinder with a flapper disc, being careful to grind only the welds. Once you get it ground down, scuff it with some 80 grit, check the level, adust as needed and add a slight amount of filler. Then sand, prime and paint. One step at a time and it's easy.

 

Ok cool thanks guys.