Drivers inner Rocker repair

A small section at the front of the inside rocker panel had succumbed to rust, this documents the repair procedure i used. The panel is made from 16gauge steel which made fabrication a little harder but welding easier

Very rough layout on 16gauge

Leading edge cut to shape

And bent 90 degrees to form a small lip

Offered up to vehicle

And small rib formed with hammer and dolly and rubber hammer

Offered up again and accurate cut lines drawn on

Clamped in position, 1mm gap to allow good penetration of weld.
Rusted piece for comparison!

Practise tack weld to get wire feed and voltage correct for 16 gauge

Tacked in place. Tacks then ground down and cleaned to make smoother final welds 

Stitch welded in 20mm sections

And ground down only where eventually will be the only visible part

Time to clean up!

I'm happy with the result this time, the whole process took about 3 hours to do this small piece, its a slow job but satisfying to see the results.