Just take your time and don't rush it. Make sure you get a decent MIG welder (with gas)

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1600 Build: http://ozdat.com/forum/viewtopic.php?f=59&t=22694

The big reveal.....I had a chance to have a closer look at the extent of the rust this morning, and although it looks pretty bad, I'm confident that I can get it sorted soon.

My boss, who helped me strip it down has all the tools necessary and is also pretty confident we can put it right, he is also good friends with a panel beater who he said would more than likely lend a hand when we get to fixing it.

Any suggestions on the way we should go about it? My boss had some suggestions but I'm keen to listen to advice from those of you have been there and done it.

Thats not so bad. Just take your time.

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1600 Build: http://ozdat.com/forum/viewtopic.php?f=59&t=22694

Thanks for the vote of confidence my boss also has a good gas mig welder as you suggested, glad I found it now rather than further down the line

From what I can see, I would unpick that curved panel completely, or at least back to sound metal.
Cut it off with an air chisel or grinder.
Then see what's inside
Replace all the trashed metal with new patches OF THE SAME THICKNESS.
Build it from the inside out, like the factory did, but use zinc annealed sheet.

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Regards, Graeme
Just trying to help...
http://nissanman.shutterfly.com/
graemes@internode.on.net

wouldnt zinc annealed panel be a pain to weld? In my limited experience anything that is zinc related is alot harder to weld?

That is what the industry is using now.
As an aside I use Oxy/Acet to weld all my repairs

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Regards, Graeme
Just trying to help...
http://nissanman.shutterfly.com/
graemes@internode.on.net

Yeh that is the same place that I had to repair,Luckily I worked at a Motor wreckers so I had access to the panels that I needed.That said the panels would be fairly easy to fabricate and when the guard is replaced you will not see the repair so it would not matter if it doesn't look original as long as it is replaced

Like galv you can wire wheel the surface coating off of the edge/seam your welding back to the clean steel underneath. Then primer it back up after its welded...

That doesn't look any where near as bad as the 1200 coupe I have here at the moment. It needs the dash,windscreen,scuttle and plenum removed, and new inners fabricated so your feet don't get wet. The stiffeners on it are completely gone, and the panel from the stiffener and down the side of the pillar needs replacing.

Hi ChrisTwitch,

My friend had recommended me Laurie Barrie Smash Repairs when I had a similar problems with you. You can try call this auto repair shop and get some advise.

Phone: (07) 4779 7787

Good luck!