Thoughts/opinions needed for pillar repair..

[67 Sunroof]

I took these pics today and and contemplating what I should do with this. The body is in otherwise excellent shape with this exception.
Heater channels are excellent so I am thinking of setting the whole body on a square "table" about 6'x6'x4'to begin the body work.
What should I do with this section? It is rusted through but the heater channel and tube behind are fine. Looks like water was setting in the bottom and just rusted the crap out of it. Do I tackle it from the inner fender well (cut the section out) or from the inside??
Thanks!

Another pic here:

[Mike Fisher]

Put a rotary file in your drill and carefully grind out the rust to solid metal. Treat all the rust/bare metal with Rust-Prep liquid or similar. Make a cardboard template to transfer to 20 gauge steel. Hammer the patch into shape and take it to a Muffler Shop etc and have them weld the patch in for you?
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69 FI/AT square Daily Driver
66 sunroof,67,70,71,71,71AT,72,72AT,73 Parts
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'68 Karmann Ghia sold

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[offshores]

I just recently went through that on the right side. Not 100% finished yet, but got most of it done. You'll need these:
http://www.wolfsburgwest.com/cart/DetailsList.cfm?ID=111805351E
http://www.wolfsburgwest.com/cart/DetailsList.cfm?ID=111809021BX
I also used copper pipe and pool hose for my defrost tube. I soldered a coupler to the heater channel with solder paste https://www.youtube.com/watch?v=PU15lHgTYEI and applied the POR 15 putty (white stuff) over that to help keep water out.

[67 Sunroof]

What is the wheelhouse for? Is that the outside piece that is just behind the wheel area where water sprays up behind the front wheel?
Because that is a little rough too.
What gauge thickness is the wheel house metal part?
Thanks!

[Matt K.]

[67 Sunroof]

Yeah, that's a pretty badass job!
I went ahead and ordered two wheel houses and the part you had suggested for the lower pillar too. Is it okay to cut out that lower inside section if I have the body off the pan and good heater channels? I don't want to risk the body buckling from insufficient support.
!!
Like I said, I have a 6'x5'x4' metal square that I was going to lay (2) 2x4x6's piece of wood across then lay the body on top of that to work on it. I hope that will be sturdy enough?!

[offshores]

Thanks guys. I still have a ton to learn and practice on, but I'm having fun.
After removing bondo I found this. Galvanized sheet metal and rivets. I needed that wheelhouse section to fix this.

The wheelhouse section goes here:

I cut a section that I needed, keeping as much original sheet metal as possible. I still need to fix the the upper part, do some more welding, grinding, etc... Not pretty by any means, but it's still a work in progress.

I did all this work with the body on 4 HF carpet dollies. I was at first concerned about cutting out that section too and then realized that there wasn't much structure there anyways with all the rust. Plus, I still had plenty of meat attached to the heater channel in front of my repair section. Before I welded everything up I hung the door and it was the same as when I took it off. Amazingly, it was nice and square before and after.

[67 Sunroof]

Do you have some pics of where the floor dollies are located and where you got them? You make them?
Also, I wonder if it's okay to cut ONLY the small section of rusted metal out and then weld the WHOLE piece in overlapping the existing metal or would that possibly just trap more water inside? I'm gonna seam seal all around it and then por-15 over it to protect from stone chips and such....
What do you (or anyone) think about this?
Great job though man! Looks nice!

Also have a very small spot starting in this area: this is a poor design IMO as this Is where all of the water from the holes drain into and down into the little corner and collect in that area!? There is nowhere for the water to drain to that I can see!!??
Here's two pics:

Here's the inside where the water collects in the corner:

Where does the water drain once it comes down from inside the holes above the engine??

[offshores]

http://www.harborfreight.com/movers-dolly-93888.html

Personally, I would just cut out and replace what's needed and would not overlap.