I'll probably start a thread for this whole car in the restoration section since this is what this is turning into, but wanted to fish for some opinions on this particular rust issue since I can't seem to a find a lot of similar examples.
My 87 300D has a nasty rust issue on the passenger side upper rear shock mount. The metal is thick so it isn't giving structurally, but it's bad and I need to fix it. Thought it would just be a POR job, but it is obviously not ... as usual when you dig past the surface.
The area is put together with multiple pieces of sheet metal that seems tack welded together. It looks as if, assuming I can remove the tack welds, I could just tack weld new pieces in from inside the trunk, while doing a small weld patch on the wheel well bit it mounts to. I can't find these pieces of sheet metal in the EPC or any of the mishmash of onlines parts sites I can find. Does anyone know where I can find it?
I could probably cut this out of a non-rusty car, but I'm not sure I can breakup the spot welds without really boogering it up. (Or can I?)
I will post more pictures tomorrow of this area inside and out so my question makes more sense.

Attached Thumbnails

 

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1987 300D, arctic white/palomino--314,000 miles
1978 240D 4-speed, Euro Delivery, light ivory/bamboo--370,000 miles
2005 Jeep Liberty CRD Limited, light khaki/slate--140,000 miles
2018 Chevy Cruze diesel, 6-speed manual, satin steel metallic/kalahari--19,000 miles
1982 Peugeot 505 diesel, 4-speed manual, blue/blue, 130,000 miles
1995 S320, black/parchment--34,000 miles (Dad's car)

Is that picture upside own?

Not as it's showing in my browser ... may be a sort of an MC Escher-type illusion since it's not a very good picture. This is a view inside the wheel well. The rusted area is above where the shock goes in. I will add more pictures tomorrow that offer context ... apologies for not being clear at the moment.

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1987 300D, arctic white/palomino--314,000 miles
1978 240D 4-speed, Euro Delivery, light ivory/bamboo--370,000 miles
2005 Jeep Liberty CRD Limited, light khaki/slate--140,000 miles
2018 Chevy Cruze diesel, 6-speed manual, satin steel metallic/kalahari--19,000 miles
1982 Peugeot 505 diesel, 4-speed manual, blue/blue, 130,000 miles
1995 S320, black/parchment--34,000 miles (Dad's car)

If the rest of the steel is good, clean it up and weld in a patch.

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Gone to the dark side

- Jeff

OK, more photos. The pictures from inside show what I'm talking about with different layers of metal being tack welded on. The shock bolts through two layers of sheet metal ... the one that forms the wheel well which is normal thin sheet metal, and then the smaller piece seen on top inside the trunk, which is super thick. That piece is solid, but does have surface rust on it. I can cut off all the thin sheet metal outside of it and weld in new, but I don't want to weld over any rust, so the thick piece should probably go too. My point in all this is it would be difficult to recreate in patches, especially considering I am a beginner welder with no metal-shaping ability or tools. Guess I will just cut out all the rust and see what I'm left with. Hopefully I can get the thick piece from a parts car and the rest can just use patches.

Attached Thumbnails

         

__________________
1987 300D, arctic white/palomino--314,000 miles
1978 240D 4-speed, Euro Delivery, light ivory/bamboo--370,000 miles
2005 Jeep Liberty CRD Limited, light khaki/slate--140,000 miles
2018 Chevy Cruze diesel, 6-speed manual, satin steel metallic/kalahari--19,000 miles
1982 Peugeot 505 diesel, 4-speed manual, blue/blue, 130,000 miles
1995 S320, black/parchment--34,000 miles (Dad's car)

Books

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1980 240d ,

chain elongation, cam marks reference:
http://www.peachparts.com/shopforum/diesel-discussion/10414-help-i-need-check-stretch.html

http://www.peachparts.com/shopforum/diesel-discussion/305365-9-degrees-chain-stretch.html

evap fin cleaning:

http://www.peachparts.com/shopforum/diesel-discussion/156207-photo-step-step-post-showing-w123-evaporator-removal-1983-240d-1982-300td.html?highlight=evaporator

A/C thread

http://www.peachparts.com/shopforum/diesel-discussion/297462-c-recommendations-mb-vehicles.html

I know of a certain parts car sitting in Middletown that I also need to cut some metal out of that should have those same bits you need.

If possible weld from inside the car. Welding up side down is a new experience you probably don't want to practice on your car!

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1992 W201 190E 1.8 171,000 km - Daily driver
1981 W123 300D ~ 100,000 miles / 160,000 km - project car stripped to the bone
1965 Land Rover Series 2a Station Wagon CIS recovery therapy!
1961 Volvo PV544 Bare metal rat rod-ish thing

I'm here to chat about cars and to help others - I'm not here "to always be right" like an internet warrior



Don't leave that there - I'll take it to bits!

Or... Get a body roll scaffold... MMMM tools!

https://www.accessiblesystems.com/et/et.php

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John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 190D 2.5Turbo
1987 190D 2.5-5SPEED!!!

1987 300TD
1987 300TD
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!

Or get someone else to fix it!

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1992 W201 190E 1.8 171,000 km - Daily driver
1981 W123 300D ~ 100,000 miles / 160,000 km - project car stripped to the bone
1965 Land Rover Series 2a Station Wagon CIS recovery therapy!
1961 Volvo PV544 Bare metal rat rod-ish thing

I'm here to chat about cars and to help others - I'm not here "to always be right" like an internet warrior



Don't leave that there - I'll take it to bits!

Already on it. I'll let you know when I'm headed to start cutting ... I might be able to get your floors too if I definitely know how much you need me to cut.

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1987 300D, arctic white/palomino--314,000 miles
1978 240D 4-speed, Euro Delivery, light ivory/bamboo--370,000 miles
2005 Jeep Liberty CRD Limited, light khaki/slate--140,000 miles
2018 Chevy Cruze diesel, 6-speed manual, satin steel metallic/kalahari--19,000 miles
1982 Peugeot 505 diesel, 4-speed manual, blue/blue, 130,000 miles
1995 S320, black/parchment--34,000 miles (Dad's car)

Thanks ... I'll put some of the metalshaping ones on my Christmas list. I've watched some YT videos but I need to learn more.

I should be able to do a fair bit from inside. I've done a little overhead (in class and one tiny spot on the first bit of my car I did), but it's hard under the car to find a good position to make controlled welds!

Wow, this would be great for doing the rockers, haha. Looks a bit scary.

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1987 300D, arctic white/palomino--314,000 miles
1978 240D 4-speed, Euro Delivery, light ivory/bamboo--370,000 miles
2005 Jeep Liberty CRD Limited, light khaki/slate--140,000 miles
2018 Chevy Cruze diesel, 6-speed manual, satin steel metallic/kalahari--19,000 miles
1982 Peugeot 505 diesel, 4-speed manual, blue/blue, 130,000 miles
1995 S320, black/parchment--34,000 miles (Dad's car)

Its going to be a lot. I think I need to see the floor on his car before I start cutting since I haven't dissembled anything on mine yet.