Originally Posted by 03JGMonte

Your gonna wanna weld it all, your just asking for future problems by going that route, in a few years the filler will crack where u don't weld

Originally Posted by 06mistreSS

X2 weld the whole joint. Results will be worth it and last a lot longer.

Originally Posted by The_Maniac

Sorry for the delay (just getting caught up).

As for the POR15, optimally you would want to coat both surfaces. But if you opt not to, at least coat the inside (as the rust damage is from the inside out).

Areas no one sees, you can brush the product on (and it actually flattens out nicely). Make sure to remove any loose material or debris (best results are going to the bare metal if possible). And make sure to use their "metal prep" product. Helps etch the metal.

In areas that will be seen or painted, try to spray the product (as I understand, to maintain the chemical bonding properties, you must thin it with their thinner).

Words of advice:
- Where gloves. I speak from experience, get it on you and you will spend 1-2 weeks for it to come off your skin naturally (no scrubbing ever seemed to work).
- If you don't use the entire can in one use, place a double layer of syran wrap between the lid and the can (if possible, have the wrap dip into the can and avoid air between the POR15 and the wrap, helps it last longer).
- Lastly, when applied by brush, that stuff bonds very solid. Sanding to feather in could be a pain in the butt. Hence why finish/exposed areas I recommend spraying it (I have never sprayed POR15, but when helping a friend with a Jeep years ago, we learned it does not quite "sand" down easily).

Originally Posted by lougreen03

Wow that looks like a big job but your making good progress. Body work is one skill I wish I had.