I found this on a forum I visit and feel it is such a good example of rust repair and fabrication at home I had to post it here. YES you can do it. YES it can be done at home with few tools. YOU can make these parts yourself.

Brian

http://www.chevytalk.org/fusionbb/showtopic.php?fid/80/tid/205536/pid/1588971/post/1588971/#1588971

That guy does some great work. A real craftsman.

That is some VERY nice work. I thought I was pretty decent. I need to step up my game.

Outstanding Work!

Certainly a nudge for people unsure of their capabilities. I've been fabbing for over 20 years and respect someone who takes initiative. Let's face it, bodywork is not that difficult. Willingness, patience and perserverance are but a few key elements. A local blacksmith near me can humble any bodyman. Bodywork does not hold a candle to custom swordmaking from raw ore. Anyone in the market for a $40K sword and scabbard?

Impressive!

Completing a job like that is very satisfying... the hours invoved are unimaginable for a novice though... TRUST ME!

Very impressive this guy has some patience I thought I was tedious he has it all over me.....

Completing a job like that is very satisfying... the hours invoved are unimaginable for a novice though... TRUST ME!

You can say that again! I'll bet he is not a weekend car restorer!

Those are some skills I'd love to have. Just watching skilled craftsmen do this still just blows me away with how easy they make it look.

I can't come close to that level at all.

Maybe someday/year/decade.....

I will get to it though. A goal I have.

Those are some skills I'd love to have.
you do now
Like the guys above say "Let's face it, bodywork is not that difficult. Willingness, patience and perserverance are but a few key elements."
But hey, that spplies to damn near eveything any way...wireing refurb the home what ever.
All u need is a few of the right simple tools, commonsense, and a bit of forethought.

But then the mentality of todays world is 'rip 5h1t and bust' need it now, buy it off the shelf

My old man used to say "if it was made once, it canbe made again...and we have better tools now"

Guys, I know this man is very good, he does it effortlessly. But don't loose sight to the reason I posted it. I didn't post it so you would look at it and drool wishing you could do it. I posted it because you CAN do it.

Go out and try, look at those photos he posted. He cuts off a piece of metal. Looking at just that piece he takes JUST A PORTION of the piece and makes one like that portion. He then takes another portion of teh piece and makes on like it, and so one. He makes two, three, four, "bite size" pieces and then welds them together into the one piece to replace the rusted out one.

I have done it, I am not going that sort of work these days or I would do a "how to" for you. But this man has done it, it is all right there.

Forget about the press, forget about all that. Take a small bite sized piece and make a pattern, then bend that piece using the vice, home made dollies, what ever.

It really isn't that hard guys!

One thing I used to do was to cut that piece out, then flatten it with a hammer on a anvil. Now you have the exact shape of the piece to cut the new one out. I then drew lines on the new one where the folds went, and put the folds in, trial fitting it to the place where it goes.

All I know is, it IS possible to do this stuff as a home hobbiest.

I have said over and over, the only difference between putting a coat of wax on your car and doing a frame off restoration is the amount of steps it takes to do it.

Take each one of these tiny steps and put them all together and you have a restored car.

Don't be caught up in how skilled he is or the tools he has. YOU can do this!!!

Brian