How to Treat Cutaway Rust in Car Restoration

"Hi. I'm Doug. I work with twenty great guys in St. Louis at Doug Jenkins Custom Hot Rods and we are going to do some work for you today on Expert Village. Now, Alex is going to be using a little nematic cut off tool. It has this chrome guard on it so it doesn't shoot sparks and bits of car in your face when you are using it. He's cutting along that line that he free-handed with a magic marker in order to remove the rusty metal and give us a good, strong surface to do our repairs to. The reason he's cutting what looks like otherwise good material is the rust. You can see where metal is missing; that's pretty clearly rusty. But, the metal beyond that will be partially rusty. So even though it's nice and shiny on the outside, on the back side of it, the rust has been eating at it a little bit and we'll want to make sure we get a full-thickness metal that has as little rust as possible. And Alex has done lots of this, so you'll always notice that he holds the tool in such a way that the sparks are going away from himself. You don't want to be grinding and having the sparks head towards you. You can always position the grinder and yourself in such a way that the sparks go away from you and not towards you."