I have been looking all over forums, and YouTube to find the best/longest lasting rust repair process. I just bought a 1980 Toyota Pickup and it has a few rusts spots on it that I am looking to repair myself so I can learn how to do this. Ive seen people weld in patch panels for rust that has gone all the way through the metal (like in my case), and I’ve seen some strictly use bondo and metal mesh for rust repair. Any advice is greatly appreciated, and thanks in advance!

The only way to do it properly is to cut it out and either patch or replace panel, or part thereof. Bog and mesh is not an acceptable way to repair rusty panels, nor is it permanent.

Holes like that in the roof would lead me to think that there may be some real horrors in hidden or covered spots. Have you assessed it fully to establish whether, aside from the practice value, it's actually worth the money it's going to cost to fix that poor old thing?

I agree. The rust is always worse that it appears.

You can see a small rust through area like a crack in the sail panel just above the seam. I have already removed the lead from the seam and drilled out the spot welds preparing to remove the roof skin.


This is what I found under the roof skin. Notice how much larger the rusted out area is than what was showing on the outside:


This car is a 1968 Plymouth GTX so it's value makes it worth fixing otherwise it would be not be worth the time and effort.

What matters now is if your truck is worth it to you to spend the time and money to fix it?

If this is a project to learn on, then expect to invest way more money in tools, supplies and materials than the truck will ever be worth. Do the job right and remove all the rust so your vehicle will look good and last a long time.

Thanks for the advice! To me, fixing it is the best option and that is what I have chosen to do with the truck. From what I'm hearing, the best way to fix these rust holes is to weld in patch panels. That leads me with another question. Would the "Lincoln Electric 120-Volt/88-Amp Mig Flux-cored Wire Feed Welder" work for this particular application? I only plan on using a welder for this truck, and very rare household projects.

You should post that in the Metal Fab and Welding forum where the real knowledgeable guys hang out.

You probably aren't going to like my opinion but I'll give it anyway.

If you are looking to restore this truck and put a nice straight shiny paint job on it, you're in for a lot of work and a lot of money for a vehicle that isn't going to be worth very much when you're done with it. If you just want it to look one uniform color and just kind of take it off road or get you from point A to point B, then I'd just do a hack job repair on that roof and be done with it until it starts to fail.

To fix it correctly you'll need a MIG welder that can use gas. If yours is flux core only, you're out of luck for thin sheet metal like what's going to be on that Toyota. But lets just say you already have the full welding rig set up and you're ready to tackle that roof rust....what are you going to weld your new patch panel to? I highly doubt you'll be able to weld to anything in that channel because the sheet metal is likely so rusted that you'll just blow right through it as soon as your welder touches it. It more than likely will need the entire roof skin replaced.Also, where are you going to get the patch panels? I don't think they're available in the aftermarket so you'd be scouring junk yards and the internet for a less rusted roof than your own to try and throw on.

If it was me, I'd get rid of the truck, even if I lost some money on it because I'd lose a lot more trying to repair that. If it's a family heirloom or something then by all means do your research and try to fix it but you'll need to do some major studying because fixing roof rust like that isn't as simple as cutting off the bottom of a quarter panel and welding a new patch panel on.

ESP47 Is spot on
Your gonna need a Whole roof plus drip rails to fix the cab and thats not even the bottom of the rig then theirs the Tail gate and the Quarter panel looks rusted too?

Not gonna be easy or cheap to fix right

I've had cars shipped cross country for $1000-$1500
This guy is willing to take offers, but he needs to send some pictures. It has a long list of new parts
https://bellingham.craigslist.org/cto/d ... 12890.html

Yep, I'd agree with Chevman on that. Cheaper to have something shipped in "better" condition than to throw parts at a rust bucket with the "hope" that it's going to recover. I bought a car last year which would have been about $12000 to $15000 in my local market. Found it already pretty much "done" out in Vegas for $6500. Totally rust free. Insured shipping to my door (about 2000 miles) was $980.
On a side note.... I noticed you asked about a "flux core" welding rig for doing this.....if you are even asking about that type of welder for a project like this..... You need to do a lot more reading about rust restoration.....just sayin'........

HattedToast wrote:Thanks for the advice! To me, fixing it is the best option and that is what I have chosen to do with the truck. From what I'm hearing, the best way to fix these rust holes is to weld in patch panels. That leads me with another question. Would the "Lincoln Electric 120-Volt/88-Amp Mig Flux-cored Wire Feed Welder" work for this particular application? I only plan on using a welder for this truck, and very rare household projects.

NO You do not want a Flux core welder'
If your going to use a Mig you need .one that uses Gas.
Preferred methods for repairing thin Auto sheet metal is Oxy/Acetylene Gas welding, Tig welding, and Mig Gas welding.
European, & Asian metal is not much fun to weld.