repair does *not* have to look pretty - it can be kept with a
carpet/mat and
never been seen.
The same mat that is largely responsible for the initial rust comes to
mind!
can't recall if it produces toxic fumes or poor/weak welds (one or the
other) so don't buy any galvanized sheetmetal from Lowes, etc.
Perhaps both. For sure the vaporized zinc is _not_ good for you, at
all.
Gump is just nice enough that it ought to be worth finding out the
actual price of the 'right' way to fix it, before going down any
other path. There is _nothing_ more satisfying than welded metal,
even if you do have to have somebody else do it!
The Frankenheap is much too far gone to waste any real money on, welding
on flattened tin cans, etc. is by far the cheapest patch there is.
But what a fine beater it makes! I'm looking forward to driving it
again, once the 240D leaves us. (Or at least once its second tank
of fuel is largely consumed. We had to fill it again to check the
mileage after the big road trip, but I want to get my $110 back out
of it before it goes.)
-- Jim