Got a few panelwork related questions.

What size wire should i be using in my welder. I currently run 0.9mm for general purpose, and find that running the welder amps low makes it hard to get a good pool. I suspect Ill need to drop down, but to what?
The welder is a 220amp cigweld MIG.

Also looking for some opinions/advice on how best to tackle rust holes in the panels.
The last bit of rust to tackle is in the rear boot wells. (Where they all rust)
The parts requried are all below the lower crease, so the panel is only bending in 2 directions.

I have some 1.5mm, and 2.0mm sheet steel laying about (old signs...)

I spose its just a matter of cutting out the rusted section, cut out the replacement steel, and spotting it into place.
But thats where I get concerned. I have learnt that if it seems easy enough, then you have missed the point. There is a reason there are panel beaters witha 4 year apprenticship.

Any hints?

Oh and since I am now starting on Daisy after a 3 year hiatius, ill start a build thread, and move this to there.

0.9 is ok but you will need it to be on low amps or you will heat the steel up too much and warp and also blow holes every 5 seconds...when cutting rust out the hole is usually bigger then you think it will be as it spreads and you want to make sure you get rid of all of it. welding to rust is not fun as all it does is melt away to nothing everytime

Hi reuby_tuesday

One mistake people do is 1st to CUT Rusty Part

- FIRST - DO THE NEW METAL PART
- SECOND - MARK IT OVER THE RUSTY PART
- THIRD - CUT IT OUT
- FORTH - WELD IT

I thought it was the other way round?

The way that fazpioes said means that the replacement part is a perfect fit to the panel as opposed to cutting a hole first and trying to cut a replacement of the right shape and size.

I think it works for some situations. I guess you could cut a shape using the rusty part you've cut out......each to their own?

Yeah that makes sense, with my car the rust just kept going!
So I started cutting it out first then making replacement sections and I'm still going :(

Use .6 wire

Can you get 0.6mm flux core wire?
I might try that, makes sense. Will I have to change the Tip (currently 1.0mm)?

pretty sure you can i use .8 most of the time but i reckon .6 would be better as it wouldn't put so much heat in the thin metal that it will bend or buckle when cooling down....