I've started removing and replacing the cancer circles on the top on the fender apron. I don't think all mustangs had it but I have 4 spots on my 69 coupe. Two on each side.
The first was trial-error. I first had to cut out the corroded area and then replace it with a new patch. I had some salvaged sheet metal that I used for the replacement pieces. I found that the shock tower is made of thicker steel so I had to cut 3 squares just for that piece and then one more to make up the total thickness of the apron piece too. After spot welding the three pieces together I welded that onto the shock tower steel then the last piece on top of that with a couple of spot welds in the center area as well as all around the hole.
I haven't done any of the other three spots yet. I was hoping for some input from any of you folks. Is there an easier way. The aprons themselves are in pretty good shape and I really don't want to replace the whole panel pieces.

Here are some pics of what I have done, if that helps

 

Ford used too much overlap on these panels, so this rust was standard equipment on all 67-70.

 

I agree, pretty common, exactly the same on my '67, 2 on ea. side. There are ~5 spot welds in a circle and once water gets under the lip it ends up in the center of the weld circle and starts rusting. Nice job on the repair, I had to pay someone as I don't weld yet.




Take a close look at your battery apron, also common to be rusted/rotted from leaking battery acid.
Jon

 

I wondered if those circles of rust were abnormal. I have the same ones. Repair looks good!

 

Thanks Jon. I am welding with the shieded wire still so it takes longer to get a good looking weld. Some day I will buy the tank and shielding gas.

 

Trust me, once you start using the gas you will never want to go back. Especially when you start doing any sort of bottom side welding.

 

did you use weld thru primer?

what do you use to grind your welds?

 

No, I should have thought about that. I haven't gotten to the other 3 spots so I will pick some up tomorrow. Thanks for that. I am using a 4" grinder with a cutoff wheel. It gives a smoother looking grind.

 

have you ever used a small roloc on a right angle air grinder? the smaller tool and discs make it easier for me to control and not turn the surrounding metal to the weld into paper.