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Originally Posted by R Leo
What about down inside the joint? I can't mechanically clean that; will the acid core solder do it?
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No it won't. and where there is rust you won't get solder flowout either.
How heavy is the metal? Is sandblasting as much as you are able an option?
Is it a light enough guage you can open the joint to clean it somehow and close it back up with a hammer prior to soldering?
Even better are you able to post a ppicture of the joint in question. Maybe a "Patch" that overlays the joint is an option, assuming its flat enough.