Just get some new wire and start doing spot welds and don't try to run long beads. My younger son did a whole lot of that on the old 4Runner that we had and did a pretty decent job rebuilding the metal over the rear wheel arches and the rear quarter from the arch to the back of the panel. He just tacked and then tacked between until he had it filled in. Used a flap disk in a grinder to flatten the welds and it all looked pretty good when he was done. It was fall and too cold to paint so he sprayed it with rattle can rock guard and let it go but if he had been able to smooth a bit of filler over it, it would have fooled most folks into thinking it was original.
He had little or no experience welding.
The welder is a Lincoln Migpac 180 with gas. I had a more basic 120V unit first and had very little luck with it. It had the gas setup too but like yours, little control of heat or wire speed. I gave it to my b-in-l and bought this one on a good sale. Kept the argon tank and made my b-in-l get his own tank.


On 15/06/2015 4:10 PM, clay via Mercedes wrote:
Not headed to do the project just yet.  I will make a few pix for fun.

AS for welding torches and such.  I kind of felt it would be less controllable 
and flammable than poking arcs and wire.  I am not that good with flames, and 
the arc would be a bit more surgical.  Going in, I was not aware that sheet 
metal was such a complex process.   The gobs of epoxy and fiberglass were not 
going to do the job, as they were delaminating and the rust was not dealt with 
on the underside.  May as well put metal back for a solid repair.


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