A good sharp set of tin snips is a worthwhile investment if you’re tackling a job like this. Leave yourself straight edges to weld on to. Shape a steel patch to fit roughly, and then cut to fit in place. Alternatively use a cardboard template first to make sure you get it right. And here’s one we prepared earlier.
Shaped the repair patch and MIG welded it in position. It will need painting. This rear cross member is normally hidden away under the rear bumper. It was rusty but could be repaired rather than replaced. It’s important to cut out all of the badly rusted metal before shaping and welding in a patch. We advise wearing protective gloves. Patch has strengthened the cross member considerably. As you can see, it’s still rusty in some areas but that’s mainly superficial.
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