Replacing rust holes with replacement metal.
Here you can see a poor previous repair that was full of bog and had rusted out. This looked really bad, but the surrounding metal was still in good shape. Filler being nearly half an inch thick isn’t good at the best of times, but when it is on top of rust, it is terrible.
The area was trimmed back until good metal was found in all directions. The replacement section was made from 1.2mm thick steel sheet, and can be seen sitting on top of the door opening. The sill panel on an EJ-EH is thicker than other panels, as it is part of the chassis structure of the vehicle.
With patience and time, any terrible area can be made good again. You can see there the back door was left on to make sure the gaps all lined up. There was a small bit of rust repaired on the dogleg also. It was not bad enough to warrant replacing the dogleg panel.
After being primed up with two pack red oxide primer (Spies Hecker Red Brown). The repairs are finished off with some fine filler. This is a little different to bog, as it is less porous, and much finer. The average thickness after this repair was done was about 1 millimetre. The thickest was covering where some of the original lead had melted at the bottom of the dogleg. This is a big difference to the hacked up bog job that was there before.