Rust is never fun (welding is fun though). Especially when your screwdriver goes straight through what you thought was metal.
I used an angle grinder with a high speed wire wheel to get that thick paint off. Then using the angle grinder agian I cut the peice out carefully. Don't cut to deep there might be something on the otherside.
Ok. Welding it is the tricky part. You are going to end up blowing through the weld several times so don't get frustrated. You need to "tac" it in place first on a four corners. Weld just a small amount then do the same to the other side and let it sit untill it cools. Repeat this over and over untill you have completed the whole weld. This way it won't warp and bind the metal from the heat differences. After that you will want to use a grinder to smooth out the bead and bondo over it later to make it even smoother.
