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Originally Posted by canadian21m
what if i clean it out and use bondo? and i will try to get to few better pictures tho
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Bondo is the last thing you want under there. It's a talc based body filler and being natrally porous. Will let water vapor collect inside of it and eventually rust again.
If you don't have access to welding equiptment. This is not a perminant fix. But it will last.
You can use a wire wheel to take off all of the undercoating. Take a die grinder and a small rotory cutting tool. Mostly a dremmel. And clean out all of the rust to bare metal. Get a clean plate of metal to go overtop of the area, overlaping all of your seams by atleast a half inch, a full inch is best.
Use a 3M pannel bond. It's a structural adheasive. It's the same thing Chevy uses to hold the body pannels of the Z06 Vette as well as Porsche uses it on their 911's. It's very very strong. Then have someone tack weld the corners. You might be able to talk an exhaust shop into doing it. Or use self tapping screws to hold the corners down. The only weekness of Pannel bond is that it can pryed up from a corner, but it's just as strong as a weld to Tensile (pulling) and Compressive (pushing) stresses. The tack welds or screws arent needed but they are added insurance.
Then you can use an appropriate undercoating for your weather conditions. I have to look into the POR-15 products that VIP09 mentioned. I've only undercoated one car which was an AW11 MR2 that was done with rhino liner for track use.
To really fix the problem a new piece should be stitch welded in.
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