rust holes

[runningred92]

I have a 92 XLT and almost identical holes under the rear doors. I have removed most if not all the rust and sanded and primed for now. Need a couple pointers on what to use. bondo? should I try and cut out pieces of sheet metal? I dont have a welder only a cutting torch. are there any aftermarket bolt ons for under the doors that are diamond plate etc?

 

[jd4242]

lmc they are called doglegs

 

[Roadrunner777]

I'm doing pretty much the same thing. Here are the steps, assuming you have a through-hole bigger than 1/4":

1. Grind off anything not solid metal.
2. Apply rust remover, naval jelly, phosphate, whatever to deal with the remaining specs of rust.
2. Spray etching primer everywhere I can get it.
3. Take galvanized sheet metal, and find some way to work it in behind the hole. Then, bond it to the existing metal in some way. I use stainless steel pop rivets and find some way to dent them in below flush.
4. Apply bondo over the metal, and sand to correct profile. The thinner the bondo layer the better, so spend time on the metal patch.
5. Apply bondo patch glaze to fill the pinholes and small defects.
6. Primer and paint from spray cans

It is not great, it is cheap and dirty. It looks a HECK of a lot better than a rust hole, but will not come close to matching what the experienced people here can do. I bow to their skills.

 

[runningred92]

thanks Roadrunner. The truck does not need to be pretty or perfect I just dont want holes there and also being under the back doors where my 4 year old generally climbs in I dont need him to try and use the holes as a step or cut his leg.

It is not great, it is cheap and dirty. It looks a HECK of a lot better than a rust hole, but will not come close to matching what the experienced people here can do. I bow to their skills.