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Thanks for the links ddiesel. Some good informaion there.

AS I suspected Ill need to get some 0.6 wire and tips, which is fine. They are consumables anyways.

Now the challanging part. Bending the replacement steel to match factory crease lines and bending. I guess thats just paitence and triming, and hammering, and rolling.....

Its a pity im not at home to post a pic of what Ive got left. The vast majority was done for me by an awsome panel beater, but I can afford to pay him to get it all done. (it seems cheapskates are a common theme amongst datto owners......)

Yes you need to use a .6 tip otherwise the wire will tend to jump around all over the place and make sure that the wire feed wheels are for .6 also or the wire will slip instea of feeding correctly

Depends on the thickness you are welding.
GENERALLY
0.6mm for datto panel steel which is < 1.0 mm.
0.8 is OK for thicker stuff.
Thinner the material the lower the current and the slower the wire feed.
Use gas for a quality outcome.
READ a lot before starting & PRACTISE lots b4 attacking your datto seriously
http://www.autobodystore.com/new_page_11.shtml
http://www.autobodystore.com/door_rust.shtml

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....

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

Use .6 wire

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 :(

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?

I thought it was the other way round?

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