Thread: Welding body panels

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I'm wondering about body panels, I want to weld all the holes up on the body, most of the holes are about 1/2" x 1/2", some are larger. I have gotten most of my info from tex Smith's 'All about Custom Cars'. It's a great book, but some of the sections aren't too clear. He says to take a similar gauge steel tac-weld weld it in to place then, lay a bead around the hole. He also mentions to use a plastic body filler to get a final product.

Now, to me, it seems that if all the holes have a bead around them, it should pull the metal tight up against the body panel and a good grinding then a good sanding should get you a quality finished product. Please point me in the right direction.

Normally you would place the new metal,which is slightly larger than the hole behind the hole. Once welded, it will be slightly recessed thus, the need for bondo.
Prime the area after grinding w/epoxy primer then place the bondo oner the primer.
Don

Go out and get you an old "junk" door or fender .... " and try it"
then you'll see what they mean !

you really should practice on something else first anyway ....
you'll get a lot out of just practicing first ....

Thanx a lot Don. That makes sense, sounds easy enough too.

I guess its probaly just a preference for doing it a certian way but anytime i have shaved handles or locks or any small body "smoothing" i alway cut the metal to the size of the hole instead of placing behind it. Then tack weld around the seam from side to side till all the tacks join together then grind it smooth. Alot of times when doin it this way no filler is even needed.