Rust repair/body work question

[ReaperBJJ]

I've been fixing all the dings, dents and rust on my 240 so that it can be repainted. Most of the surface rust I've sanded off and used Naval Jelly or Rust Bullet, but I'm just now starting to tackle the really bad stuff.

Right now I've just cut out all the rusted away parts of the rocker panels and it has left with me with a 12" lock hole right in front of my rear wheels. I already have some sheet metal to make new pieces out of but wanted to know how I should fasten them in.

Should I rivet it or weld it? Also if I weld it should I make it a little longer so it can overlap underneath the old metal or just butt up the old and new metal and weld the seam?

[IanS]

Ideally you want to cut the new metal to fit exactly with a slight gap. Start by spot welding around the gap, making a weld every 3 inches or so. Once you go all the way around, allow the metal to cool slightly and then repeat. Keep going around until you have closed the entire gap.

I know this sounds like over kill, but if you attempt to just bead weld it, you will either burn through, or ripple the metal. Sheet metal, especially that which is as thin as a car body, is very very difficult to weld properly, I would suggest doing all the prep work, then bringing the car to a pro welder.

Once you have the whole thing welded in, grind off the excess, use body filler to fill imperfections, primer, then paint.