SunnyDaze - If you've got panels to practice with and a welder then just go at it. Try and join the panel in as many ways u can think of to get a feel for how the metal sticks together with the weld.

Start with the mig on the lowest setting with the wire feed less than half (I used setting 4)

Its exactly like soldering but with much more light. The fireworks really throw u off in the beginning but do at least 50 welds on ur practice panel, look up welding vids on youtube and read as much as you can it not rocket science and once u get over the shock of the arc starting you can see what ur doin fine.

Oh and take the grinder to your rust, you may be suprised just how much metal u find underneath.

Good luck and remember, its only metal, it can always be fixed.

ususally use about 1mm for panels, can go a little thicker if you want as it is a pillar...but 1mm thick good metal will be better than whats there

Thanks for the replys. Yeah I've never welded anything but I'm somewhat keen to try. I suppose it's like a bigger hotter version of soldering. Hearing a keyword like gasless mig gives me something to go on. I've got a couple of panels I could experiment with. I guess I could try and borrow one and see how hard it seems. What thickness of sheet metal does one use for this kind of thing?

And no not too concerned if its rough, just want it fixed. It is just a 120y after all.

Yeah mate thats it
just have a go, can't hurt....

Untill that boiling lil blob of molten hot metal bounces off the ground behind ur head, off the inside of the welding mask and onto your cheek causing massive damage to your forehead as you smash it into the underneath of the car in an knee jerk reaction trying to get out of there a fast as possible. It only hurts then... Oh and when you forget that the practice thing you are welding is like a million degrees and casually pick it up to inspect your work...
It hurts then too.

The great thing about metal work is if ya dont like how it turns out, well, out with the 4inch and do it again

lol, im in the same boat as you- gasless mig and going to weld some sheet metal and stuff.

I dont care if a bit rough, just want rust be gone!

Yes indeed

Its heaps easier to weld the A pillar

structural = thick metal = easier to weld than thin rusty zorst, esp with gasless wire.

Strength wise - its just sheet steel, not gonna hurt it with the mig - now welding a sway bar or brake component...

hmmmm maybe not

welding exhaust a bit different to welding an a pillar that contributes to the structual integrity of the car

my $0.02

Just get in there and have a go with the rust repair / welding stuff.

I had no panel work knowledge when I cut out the rust in the rear of my 120Y and fibreglassed it up but it turned out passable - for what I want the car for anyway.

I recently learnt to weld by doing the exhaust on my 200B SSS.

Rusty mild steel exhaust + Gasless Mig + welding noob upsidedown underneath a car = not very good result initially, but kept trying and got there in the end.

Dont be scared to have a go and the "mystery" will evaporate in front of your eyes.

DIY by a beginner is never gonna be showcar quality

At the end of the day tho all work you do will have to pass your own personal quality control so at least u will be happy with it in the end + learnt some useful #OOPS#e along the way!!

my old man's a great fabricator. You might have seen some of his stuff on here for sale... the floor pans and drip rails...

ok easy repair for someone with a welder, cutting the rust out and making a new bit to fit the hole is pretty easy, then just need to find someone with a welder