Need advise on fixing large hole in bodywork
Discussion
I'm fixing up an old Toyota van and have discovered a great big hole in the passenger door sill. It had been filled sometime previously but rust has started bubbling through again, so I dug it all out and found this mess.
The hole is approx 8 inches long by 2-4 inches wide and there's a void behind it about 2 inches deep. It's not too clear in the pictures but it goes back from the outer white body panel back to the silver coloured material (looks like a takeaway tray!).
I'm aiming for a reasonable cosmetic finish (it's only a white van after all), but my priority is to prevent the rust spreading further. Prior to welding/fibreglassing over the hole, I'd like to treat the metalwork to prevent it bubbling agian. The inside surfaces of the void are also rusty. My initial thoughts are trying to paint waxoyl or similar in there (but it's difficult to get at/paint without missing bits) or of using expanding foam to fill the void. Does anyone have any other suggestions or recommendations?
Or should I just get it all cut out and rebuilt/rewelded? I'm on a budget so want to minimise cost as much as poss and do-it-myself as much as I can (I can't weld).
The hole is approx 8 inches long by 2-4 inches wide and there's a void behind it about 2 inches deep. It's not too clear in the pictures but it goes back from the outer white body panel back to the silver coloured material (looks like a takeaway tray!).
I'm aiming for a reasonable cosmetic finish (it's only a white van after all), but my priority is to prevent the rust spreading further. Prior to welding/fibreglassing over the hole, I'd like to treat the metalwork to prevent it bubbling agian. The inside surfaces of the void are also rusty. My initial thoughts are trying to paint waxoyl or similar in there (but it's difficult to get at/paint without missing bits) or of using expanding foam to fill the void. Does anyone have any other suggestions or recommendations?
Or should I just get it all cut out and rebuilt/rewelded? I'm on a budget so want to minimise cost as much as poss and do-it-myself as much as I can (I can't weld).
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