Thread: Rust problems

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Well now that I have the frame welded in the car, I started trying to fix some other things. I cut out the dash and have removed the fresh air box under the dash. This was almost totaly rusted out from water and other junk getting in to the vent in front of the window. This is where the problem comes in, the top part of the vent box is the metal that runs in front of the window.
Now since most of the seam which there were three pieces of metal spot welded together, was rusted. The three pieces are the metal in front of the window, bottom of the heater box and the sides of the cab which are forward of the pillars below the front window. The part that runs in front of the window is pitted and really thin due to rusting from the inside out.
Since most of the seam was rusted thru I cut it off and decided to weld a piece of flat bar acrossed the front of the cab.
I then shaped the flat bar to follow the body lines in front of the cab.
Because the metal is so badly pitted on the bottom I am trying to weld it up higher and have cut the lower part out. I have cleaned up what is left
and have welded the flat bar on the front of the cab.
It was a good thought, but because the metal was thined so bad the welder
even on it lowest setting wants to blow thru.
So I ended up with a messed up weld beed where I had to try fixing parts that wanted to blow thru the thin metel. Instead of the clean look I was looking for. I could grind it down and throw down a fat beed weld all the way acrossed or should I just cut out the whole thing and start again.
Oh and the window vent is so cut out and sealed up.
I'm not going thru this again. Kurt