this can be done with fiberglass & without welding, but panel adhesive is needed.


first is important to know that all of the rust must go for the repair to be permanent. think of it as cancer, if all of it is not removed, then it will start growing again.
Im using this repair I did to a 95 bonneville as an example.


first scrape down to bare metal, to know the extent of the problem & dicide what needs to be cut. dont remove the area yet.


cut & palce a piece of fiberglass cloth on top of it. add the resine & mold to the shape of the area. do this two times. Ill explain why latter.



after removing the pieces of fiberglass, finish cutting the rusted piece out.



and clean the area down to bare metal so that no rust is left.



I treated the area with POR-15. Ive had good results with it.

now cut one of the fiberglass molds the same shape as the hole, but about half an inch biger all the way around.


then cut it into two pieces and gule it inside the hole with the panel adhesive.


then cut the other piece of fiberglass the same size as the hole and glue it in place.


cover all of it with more panel adhesive, let it dry and sand it out.


if you have low spots ad some more adhesive and sand again.


then just paint over it.

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2001 Blue SLE - 1995 Black SSE - 1988 Black GTA