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Hello. Today I am doing some repairs to my Hyundai Pony pickup. It has some bad corrosion around the rear wheel arch and sill areas. I cut all of the rust out and welded in new metal. I used some steel with a zinc coating called 'Zintec'. It is easy to work with and resists future corrosion better. Here is the rust I had to fix...



Also, in the picture above, you can see there is a big dent in the side of the truck. I managed to straighten most of it out!

First I cut away all of the bad rust. Here you can also see there are some rust holes in the chassis. I will fix these too.



Then I repaired all of the inside areas that normally cannot be seen...



This is 'Zintec'. I measure the truck sill to work out what I need to make and how to make it. Sometimes I use paper or cardboard to make templates. I have a small metal folder that helps with making parts like this.



Below you can see the repair piece I made to weld into the sill. When I fit this panel, I weld through the holes along the lower edge so it is neat like spot-welding but at the top I seam weld. I use a MIG welder made by 'Portamig'...



I also made a piece to repair the wheel arch. This was folded and then shaped into a curve using my metal shrinking / stretching tool...



Here is the finished repair with all of the new metal welded in. It is not completely perfect yet and will need a little body filler to finish it...



Next, I have to fix the rust in the chassis. I have started that today and will finish it tomorrow so I will post some pictures then.