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I've been using steel bar stock and sometimes it inadvertently becomes part of the repair!

Don't ignore the value of clamping a heat sink when you have access. It makes all the difference for me since my MIG is a non gas rig. The smallest flux core I can find is .030. 025 is better for sheet metal but you need a gas unit.

Got the battery tray out and am planning on using POR15 after clean up. Also have cage nuts on order from McMaster. Appreciate all the advice.

Like the energizer bunny...just keeps growing and growing and growing.

There is more. Under the jam is gone. Have to pull battery tray to cut it out. Then figure out how to weld from underneath. Good idea on washers. I've been using backer strips but I might try washers this time. Thanks. And then there is LH side.

Like an iceberg, it was worse than I thought. It had a fist size blob of bondo in there.

So after you cut it out did you go back with the square nuts in cages or weld in standard nuts? I got the bolts out already. The ones in the pic were to protect the threads when I sand blasted them. What is the thickness of that structure you cut out?

Need some ideas on rust repair for my M35A2. The fenders attach to the cab structure with 3 - 1/2” bolts. On both sides this is a major rust factory. RH side has no access to the nut side on two as they inside the channel structure. Top point is open access and is good, middle is very loose...