For jack post rust, what is typically done? I was thinking that the only way to really get in there is to cut the fender as shown.

Judging by the sill and jamb, you may need more than a jack post

Take the seat out and put a new tub under it.

Perhaps I wasn't clear enough in my oringinal post. I wish to fix this area around the jack post.

Thomas,

I did pretty much as you described. However, since I am planning on putting on flares, I just cut straight back inside of doing the 90 angle like you show. That is because I don't have to worry about getting the lip correct as I am going to cut it off. I am very close to welding back the sections I cut out.

See here for details...

http://motorsport.zyyz.com/project_914_03_04.htm

http://motorsport.zyyz.com/project_914_03_05.htm

Hope this helps!

Richard

Thomas, I replaced both of my jack posts and didn't bother to weld the top seam of the post "pyramid". Couple of justifications for that:

1. When the post is in use, the top seam is compressed against the long, so no need for a weld bead there.
2. You can't get in there to weld it anyway.

Seems to work OK that way.

-dave

Good one Joe! Started my morning with a chuckle.

Warrenoliver

I'm just finishing up the exact same repair. I didn't cut the fender. I also haven't uploaded pics of the repair yet. I'll get them for you tonight. I replaced the outer long up to the support just past the jack area, the door sill that's rotted on yours as well, and most of the hell hole with one piece from a donor car. Talk about a multi dimensional patch.

Don't you guys have some new floor mats for your Prius that you could be installing right now?

Wow, all that without cutting the fender.

You got it. Cut the fender ...
Andy

Warrenoliver
[/quote]

Don't you guys have some new floor mats for your Prius that you could be installing right now?
[/quote]

You should see what I did to a perfectly good rear trunk floor last night
. Gonna cut out some more stuff tonight. this south Mississippi heat is making me crazy.

Here is the part we cut out



Here it is in the car





I can upload more pics if you want to see how it fit inside the hell hole as well.

Looking good