quote:Originally posted by Dynorog ... I'll get hold of some 1.5 mm plate as martin suggested and fab up a new plate.
I had to repair this exact same spot in both my '77 96 and '98 95.
First I cut out the rotten sections like you did and cleaned the edges to bare metal. Then I traced the size and shape of the hole on a piece of cereal box card board and used that as a template to cut the shape out of a flat metal sheet, and bent it to the shape of the hole in the body. Then first tack welded it in place followed by continuous butt welds (= without overlap) all around, not all in the same spot but spaced about 10 cm around the edge to avoid build up of heat. Then some cosmetic grinding and shaping of welds where needed, then primer and finally under body coating.
Remove the carpets and rubber cover of the wheel well in the interior before you start welding... !
The overlap will be a source for corrosion, specially in that area. I prefer butt welds, even if it may be a bit more difficult to do, but after some trials you will get the voltage and current settings right.