Rust Repair Demo

Obviously it starts with cutting out all the bad area.
The cut out area is traced onto paper and this is transferred to sheet metal stock
The cut patch should be oversized to the template. Basically you want to add 1/4 to 1/2 inch to all edges.
The patch is then laid over the cutout and its outline is traced. You then trim the original cutout to the size of the patch. Working slowly until the patch just fits in the cutout area. Here my magnetic ground is being used to hold the patch in place.
Next the patch is tack welded in place. A magnetic ground clamp is great for areas like this where there is no place to put a normal grounding clamp.
Working in small sections and moving around the permimiter from side to side the patch is welded in place. A continuous bead cannot be used as it will apply too much heat and warp the metal.
Next a grinder is used to smooth out the welds and prepare for a skim coat of filler to smooth it all out. I find the newer style flap disks work faster and better than old solid grinding disks.
And a skim coat of filler is applied to smooth it all out.