Can I weld up these holes?

[1930artdeco]

I have these holes in the side of my rocker panel on my car. Can I weld them up or do I need to cut the area out and replace it?

 

[The Cobbler]

I think you'll find very thin metal at the rust holes and they will keep spreading, the metal sort of disappears when you try to weld them up.

 

[M.Brane]

You need .02X wire, and a copper backing plate.

Dab. Cool. Repeat.

Cleanliness is a given.

 

[Rockable]

If you're able to do it, it will likely be distorted and the rust will come back. If you could see the inner side, you would see a pitted piece of metal with thick and thin portions. You won't weld up all of the pits because they haven't all rusted through yet. If you want this to last, cut it out and put new metal in it's place. It's always worse than it appears.

There are lots of threads and videos on the web that tell you how.

 

[1930artdeco]

Thanks, I have two plans for this area: 1) weld up the holes, 2) cut and weld in a new piece. Obviously the first is easier. I can get to the back side and it is ‘rust free’. But it is thin so it may come down to plan B.

 

[slowtwitch73]

You can drill them bigger with a step drill to get to good metal, then get a scrap bolt and thread it though, mig and cut off the bolt and grind down... or cut the bolt before hand to give you a little plug.

 

[K13]

Plan 2 is the correct way to fix it. Plan 1 will lead to plan 2 in the not too distant future.

 

[APEowner]

Yeah, you should cut that out. You should also be prepared to find matching holes in the inner panel that also needs to be cut and patched.

 

[sqznby]

Once you strike and arc on the very thin rusted material your holes will be twice as large as they were when you started. Then it will be straight to plan B.

 

[1930artdeco]

Yeah, just wanted to hear the experts opinions. Plan B will probably be easier in the long run.

 

[gte718p]

I have no idea if you can or can't. They can be welded. Can you? Should you?

I looks like a flatish section with no complex curves. I would probably cut an patch.

 

[FLHCHAZ]

Do yourself a favor and put in a patch. Trying to weld and grind thin, rusty sheetmetal if going to be frustrating. Even if possible.

 

[Notgrownup]

I would grind and clean the area First to see what is under it.

 

[The Cobbler]

I would suggest watching some you tube videos , in fact I would point you to Fitzees FAbrications , he has amazing skills on body repairs

 

[djbmw]

Do you want it back to original... or do you want it to look good quickly? If the later just fiberglass it after neutralizing the rust.
If the former then shape a new peice of metal to cover the entire area thats rusted + 3 additional inches in all dimensions, mark and cut the existing metal, and tack in the new one (tiny tacks at opppsing sides so minimize distortion).. you will likely still need to reshape the new metal with body hammers and dollys once its welded in.

 

[giddygoat]

x2 for Fitzees utube esp his cut/**** method.

 

[Imatk]

Fitzees is AWESOME.

I will add.. when you cut to good metal and weld. I'm not sure if you're looking to grind the weld flat.

But if you do, be careful not to thin the area around where you grind.

If it were me and it was possible to get to the backside of your sill I'd weld it from the back and then you'll have less (if any) to grind.

Make sure you shine a light behind the new welds... pinholes are pesky and will lead to more rust if left open.

 

[Milton Shaw]

IF your car is a classic car, JC Whitney may have patch panels already cut to fit normal rusted out panels.. You just cut the original metal and then trim the patch panel to fit and weld it in with small tack welds and eventually stitch them together. Grind and finish, Bondo and sand and it's finished.