DIYOutBack.com » Blog Archive » How to cut out rust

I have posted previously about the rust that I had located around the rear window.

On closer inspection, I have since found more rust which is localized to the frames which isn’t a huge surprise.

This post will run through the steps I am taking to cut out the rust and put back a new section of frame.

The rust I am cutting out today is the left side passenger window and was discovered once the glass was removed. The job here involves cutting out the top and side of the window frame. This will require two cut outs to be made, once will be placed back into the frame and the other will be for the side of frame.

You will need to following tools and materials to do this yourself, most hardware stores offer rentals for electrical tools if you do not have them yourself so check for pricing and availablility.

Item	Brand/model Brian uses
Ruler and pencil for measuring new frame
Angle Grinder	Ryobi
Sheeting
Metal bender	Home-made
Flat Mill Bastard File	Cooper Tools

	Here is a shot of the front left hand side of the bus before i take out the window.
	And now without window.
	This is the area that needs to be cut out.
	This pictures shows you how much there is, it goes through both top and bottom plates of the sill.
	This is the same shot of that window from above, showing top and bottom plates. The rust is where the drain holes, this is a common problem.
	First step is to mark out the area that you plan on cutting out. Make sure to measure twice and write it down. You will use these measurements to make your new cut-out.
	Using your angle grinder, begin cutting out rust. Be sure to have your ear muffs on and you should also wear protective eyewear. I forget which is stupid considering I’ve had metal fragments removed on two occassions by a doctor. Some people just never learn!

	Clean out the rust and you should end up with something like this. I have used some spray paint to tidy it up but this is only short term. Next step is to make a new frame to replace the one I have just cut out.
	This shot gives you a better view of the sections cut out in relation to the entire frame.
Making the new frame sections
	Using the mesurements you took earlier, mark out the sheeting. You need to keep in mind here that this piece of sheeting is going to be bent in two places to create a three sided box. Using your angle grinder, start cutting out marked area.

	this is what your cut out sheet should look like. i will now use the bender that I made to bend metal to the desired. You can by a bender from hardware stores but i like to make things so made one up myself.
	I always file off the sharp edges of the plate before I handle it. It just saves you from cutting your hands as much.
	Using a bender, shape your cut out sheet to the shape of the frame.
	This is the piece of sheet bent, I have to bend it more to the shape of what i had to cut out. This piece is the bottom plate of that window. There will be another piece that has to be cut and be made to go above this piece?
	This is the piece bent again, to go into window.
	And here is the final piece. I will not be welding any of the pieces that i have made but instead pop rivert using stainless pop riverts. In time welding will only rust again so this should be a better option long term. Of course i will fishalene it all before installing.
	If you have measured and cut properly, the cut out should slot easily back in place.
	This is another piece that i cut and bent. This piece is the out side piece that will be riverted in. Again, I have used fishalene to protect.
	Finally, put the top cut out in and pop rivert. I will clean and sand all of it up and finally bog it up to the finish edge ready for the under coat.