i'll start by saying i'm an old school, cheap ass redneck. with that in mind, i think you're fine with covering some rust. i did it with pre fab corners but my buddy bought a sheet of alum d plate and just bent it around the corners of his fj40 to cover about 50lbs. of bondo. it looked great. it depends on what you want to use your rig for. if it's your primary driver/mall machine/chick magnet/ once in a while wheeler on easy trails rig, fix it right. grind out the rust until there is none left. replace the corners(which are way cheap) if you have to.

if you actually wheel this thing on hard trails, why even put a bunch of cash into sheetmetal? you have the potential to total it on any obstacle. why invest in treating the rust or cutting the spot out and replacing it with new sheetmetal? you will probably break the frame in 1/2 or bash the sheetmetal in until it's not even recognizible as a jeep before the cancer grows past your aluminum rust covers.

here's a pic of my jeep. the corners and rocker covers are just hiding body damage. no structural integrity whatsoever. could i have fixed it right? restored it? yes, i could have but why? i may total it beyond repair before easter. why put all the hours in?

[img][image]http://img494.imageshack.us/img494/4499/picture0063bs.jpg[/img][/image]