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Alright, I've got two patches done, a fair amount of metal, the pan seems much more secure. I've still got to do that spot near the sub-frame mount.
I read that with using gas, the metal should be clean. I get it pretty clean, remove almost all the rust (I might be welding some rust-pitted metal, some rust could still be in the pits), and I spray on some water based degreaser, rinse it off and wipe it up. Cleaning is a pain in the ass, especially for painting. I've heard good things about POR-15's marine degreaser; does that require rinse? Does anyone have any other recommendations?
As for painting, I've decided to use this "rust destroyer" they have at the auto parts store. Relatively cheap and I think it's like what POR-15 has but separate. I used POR-15 before, but I like to spray, so i'm gonna do rust destroyer and then regs primer and paint. I wanted to get that weld-thru primer, but it was more than 30 bucks for a can! Is it really worth it? I'd only use it on spot and lap welds, but I do mostly butt welds.
For shaped pieces, I've been welding on a rough patch in places and then hammering and grinding to fit. Does anyone have a better way? My way is frustrating, time consuming, and not that good. Also, I'm looking at my last patch, and I think I'm going to have to redo a fair amount. Welds are too cold--not enough penetration, and that fiberglass is terrible. Paint isn't holding on too well either.
I could really use the feedback here.
Pic #1: rusted metal cut out
Pic #2: Patched metal
Pic #3: Rust destroyer
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1983 240D 3.0T 4-speed manual, now sold 
1989 Subaru GL Wagon 5-speed Touring Edition
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