how would you fix these small rust holes.

[bautino95]

decided to replace my outer rocker panels and that just snowballed to a full tear down. Landed up replacing outter and inner rockers, A and B door pillers, cab corners, toe kick panels, and a homemade patch on the firewall by the hvac box. Sanded the cab and sprayed epoxy primer becuse winter is coming and the truck is outside. the only other rust holes i want to address are on the front and rear windshield seal areas. and some in the cab in the upper front windshield/roof corners. there was just body filler there before. I was thinking of just spot welding it closed instead. is it worth it or just put bodyfiller back on. this is not going to be a show truck. thanks.

[bautino95]

wrong pic in prior post

[bautino95]

this should be right

[ApacheNick]

The only real fix is to cut out the bad spots and replace. Trying to weld up those holes will just make bigger holes because the metal will also be rusted away from the inside, most likely. Filling them with filler will also likely fail sooner rather than later because moisture can get to the filler from the back side allowing rust to start between the filler and the steel.

Assuming that is the worst of the rust holes, they do look like they'd be easy enough to make repair patches for though.

One other thought is that if this is going to be a temp. repair kind of thing, you could fill them with JB weld. JB weld is water proof and being an epoxy, it's kind of the same as your primer. I know it's kind of hack job sounding, but I have heard of this being done as a permanent repair for small rust holes and it seems to work well provided that all rust was removed.

[nsb29]

Been there done that made patch panels and still kept burning through ended up replacing entire eyebrow on my buddy’s 64 The desert heat and sun had dried up the seam sealer in the gutter and it rusted out from the inside It looks to me like some of that roast was from the outside where your fingers at you could try spot welded that in

[blazer2007]

I,ve had good luck with Kitty hair type filler

[JJH Jimmy]

As already mentioned the preferred method would be to cut those areas out and weld in new metal. The good thing with those areas is that forming your own patch panel should be fairly easy.

You could also fill the holes by TIG welding and using silicon-bronze filler wire. Silicon-Bronze filler melts at a lower temperature then normal carbon filler wire making it easier to fill the holes while not blowing through the thin base metal and making a bigger mess.