Continuing from the last post, here is today's progress in fixing the fuel vent rust.
This was my first time working with thin sheet metal, and I learned a few things in the process:
In summary, the situation is almost remedied. Another coat of paint tomorrow evening, and a quick cut of the rusted tube inside the car should see it resolved.
I'll update this post with some better finished/painted pictures tomorrow.
![](https://farm1.staticflickr.com/847/41568971581_e650de67e4_b.jpg)
![](https://farm1.staticflickr.com/832/40857531724_b78458bb0c_b.jpg)
![](https://farm1.staticflickr.com/843/40857529494_34b8ff4348_b.jpg)
![](https://farm1.staticflickr.com/908/41568969861_78a810cebf_b.jpg)
![](https://farm1.staticflickr.com/911/40857527934_7444e96a91_b.jpg)
![](https://farm1.staticflickr.com/834/41568969401_979abc286b_b.jpg)
![](https://farm1.staticflickr.com/853/40857526274_340a7689dc_b.jpg)
![](https://farm1.staticflickr.com/891/41568968431_1598bd1e5f_b.jpg)
![](https://farm1.staticflickr.com/932/40857523714_97c9310113_b.jpg)
This was my first time working with thin sheet metal, and I learned a few things in the process:
- Don't use a reciprocating saw for fine work.
- If I had brought my jigsaw along, I could have removed less good metal on the body and made a smaller patch panel.
- Butt welding here was unnecessary, and made things more difficult.
- Lap joints would have been preferable.
- Don't try to fill in air gaps between your patch panel and the body. It'll just blow through (or you'll have to stack some welds very carefully).
- If butt welding, your patch panel must be the exact shape of the missing metal.
- Shop rags are flammable.
In summary, the situation is almost remedied. Another coat of paint tomorrow evening, and a quick cut of the rusted tube inside the car should see it resolved.
I'll update this post with some better finished/painted pictures tomorrow.
![](https://farm1.staticflickr.com/847/41568971581_e650de67e4_b.jpg)
![](https://farm1.staticflickr.com/832/40857531724_b78458bb0c_b.jpg)
![](https://farm1.staticflickr.com/843/40857529494_34b8ff4348_b.jpg)
![](https://farm1.staticflickr.com/908/41568969861_78a810cebf_b.jpg)
![](https://farm1.staticflickr.com/911/40857527934_7444e96a91_b.jpg)
![](https://farm1.staticflickr.com/834/41568969401_979abc286b_b.jpg)
![](https://farm1.staticflickr.com/853/40857526274_340a7689dc_b.jpg)
![](https://farm1.staticflickr.com/891/41568968431_1598bd1e5f_b.jpg)
![](https://farm1.staticflickr.com/932/40857523714_97c9310113_b.jpg)
![](https://farm1.staticflickr.com/882/40857523214_9a2694b630_b.jpg)
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