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1. Best way, cut old rusty metal out and weld in new metal from a rust free car. Structural rust, ie frame rails, rockers should be welded for strength if very rusty, slight rust can be POR'd (see below).
2. Almost as good, look up POR-15 and check out the fix I did on my '85 which had serious floor rust. http://www.homestead.com/volvo2/Rust.html
3. Non structural rust can be patched with many different materials, some look better than others. The main thing is cut out all cancer and treat all surface rust with metal ready or similar.
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Dave Shannon Spring Valley, California '63 P-210 '67 1800s '73 1800ES '88-240 my pages
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