Ablecraft1998 Ford Ranger tail gate rust repair series: Day 1 part 2 "Finding the Rust..."

Описание: Ablecraft's 1998 Ford Ranger, otherwise known as "The Learning Vehicle," with a four-wheel drive, manual shift transmission and 3.0 V6 engine is having its tailgate repaired. 27 years of salt and corrosion has caused rust in the right lower corner of the tailgate.
The first step in determining the extent of the rust is using a poking tool such as a screwdriver to probe the area where the rust is visible and is not. Then take an angle grinder with a grinder disc and remove the paint from where rust was found. Grind about a 1/4 inch around the perimeter of the rust area is needed because you will need a clean metal surface afterwards in preparation of Bondo filler, primer and paint.
The use of a measuring squaring gives you the numerical dimensions needed to form a metal patch. I allow about 1/8" tolerance length and width on the patch template for the final cut of the patch. The extra 1/8" allow for the width of the cutting blade, weld deposit, and but welding to have the patch lay flat with the adjoining metal.

Tools
Titanium Easy Flux 125 Flux Core welding machine
3/64th cutting blade disc
Type 27 grinding disc
WARRIOR 4.3 Amp, 4-1/2 in. Angle Grinder with Slide Switch
spring clamps
FRANKLIN 500 lb. Capacity Hydraulic Table Cart
VULCAN 0.030 in. E71T-GS Flux Core Welding Wire, 2 lb. Roll
safety glasses
Welding gloves
CHICAGO ELECTRIC Auto-Darkening Welding Helmet
1/16" sheet metal stock
Dupli-color Perfect Match "Cardinal Red" aerosol paint
Dupli-color primer
Bondo Filler
36 grit Hercules sandpaper
80 grit Hercules sandpaper
120 grit Hercules sandpaper
220 grit Hercules sandpaper
500 grit Hercules sandpaper
600 grit Hercules sandpaper
Stanley 21-293 Surform Flat Blade Standard Cut