2007 "Red Yaris" RS Restoration

[06YarisRS]

First Welding Attempt

It turned out ok, I guess. The metal will not come off. I tugged on it as hard as I could. I am no welder, though things were complicated by a number of factors including poor lighting, poor grounding for the welder and about 1/2 way through it started to rain. I had to rush my welder back into the garage. However, the repair is very solid. I will see how it turns out with the other pieces. If I can't get it sealed with weld, I'll cover the whole repair with epoxy resin soaked fiberglass mat. If I use the fiberglass, it will be sanded and boxliner coating applied. Again, noce the repair is done, I'm dumping in a 1/2 L of thin rust proofing, probably followed by some thicker stuff. This will work its way down and saturate everything, including my weld points under the fiberglass. Hope to have this side (driver's side) done (the welding part) tomorrow evening. I found a source for epoxy resin at a local boat repair place.

Template and shaped metal:



Piece held in place by body brace bolt:



Welded (sort of, lol) in place:



A little paint as temporary rust protection:



Hole drilled through metal piece for body brace bolt: