Finishing a body repair

[gigamanx]

I promise I used search first...

I found through youtube videos, posts, and research that there doesn't seem to be a definitive guide for newbies on replacing certain patch panel areas. I am working on a kick panel for the passenger side of my 1949 cab and noticed three types of joins. A lap join at the door hinge post, a butt join in the floor and a join of sorts between the lower firewall and the kick panel (maybe called a lap join also?). What I also noticed is part of this kick panel is exposed to the front fender well.

What I'm specifically trying to find is the steps to complete such a repair. There are plenty of welding guides and fitment guides, so that's not really what I mean. Here's an example from my research so far, but I could be wrong in my steps.

1. Cut out the cancer
2. Grind, scrape and wire brush all loose rust and debris until you can't get anymore debris to come off.
3. Shape the replacement area
4. Fit the new panel and cut it to the size, shape it needs
4. Spray POR-15 or similar rust-converter/protector inside the open area to stop future surface rust inside between body panels
5. Spray weldable primer on any bare metal to be joined
6. Apply panel sealer to joints
7. Attach clamps to fit the panel tightly
8. Spot weld lap joints, weld butt joints
9. Clean up welds
10. Spray bare metal with epoxy primer
11. Drink and enjoy your work


The steps I seem to be missing are the ones to do with how to seal the metal between where spot welds occur and painting the metal inside so there isn't any future rust problems popping up. The butt weld is less of a concern, but even then it seems there should be some kind of sealant for areas exposed to the elements like a floor.

Pictures as examples on what I'm dealing with. I haven't applied any sealants because I want to be sure I'm taking the right steps.

Rust removed


Por-15 painted inside for extra protection


Part fitted but not welded.