Challenging Rust Repair Location

[1940Mopar]

I've borrowed a pic from another forum members post because I'm not able to take paid of my car right now. I'm looking for input from you all to help me in how to approach this problem.

I've got rust in the front crossmember just above where the lower control arm bolts thru the member. My plan is to cut out the rusty area and weld a plate in its place. As much as I would love to make this a stock looking cross member when it's all send and done my bigger concerns is that the rust be removed and the piece be sufficiently strengthened to handle the load based on where the repair site is. I've circled where the rust spot is.

[Plymouthy Adams]

you should be able to repair this in the manner you said...you should also be able to adequately disguised this repair if you take your time..good luck

[1940Mopar]

Okay the. I'm thinking about extending the plate well beyond the necessary are for the repair. What gauge steel would you suggest.

[Plymouthy Adams]

if are going to scab the area..I would cut out the rust..weld in a patch, then grind smooth...install the overlay and weld it in place..use the same gauge metal as the stock metal your are patching...I do not have a piece here to mic and thus establish the gauge..there is online charts that will spec the metal by gauge/thickness..here is one....years ago I repaired a Porsche that had frame rot and it was a double press box frame with inner and outer skins..repaired the inner first..then the outer and made the outer a tad larger than the inner..worked just fine and looked fantastic..

 

http://www.sheetmetalguy.com/sheet_metal_gauge_chart.htm

Edited April 16, 2013 by Plymouthy Adams

[1940Mopar]

Great. Just need to work up the nerve now.

[Plymouthy Adams]

it is basically true the hardest part of most jobs is getting started...just plan it out in your mind your manner of attack..get you supplies and tools at hand and dig in...before you know it you're priming new metal