Worked on the Boss's 64 LWB

[Rokcrln]

One of my Boss's brought his 64LWB over today to have me weld up a bunch of holes in the doors, bed rails, bed side, hood, and roof. I took a few pics to show the proper way to fill holes over 3/16". I have seen way to many guys just try to fill a large hole with weld resulting in bad body warpage and a crappy job. Or they just bondo them up. This truck had teh bondo job dome by a PO that hammered in the hole before filling with bondo. I had to pull out the dents before I could weld them up. Their was atleast 50 holes to fill and half were 1/4" and 1/3rd were 1/2".

Here's what I do. First you need to find all the holes (found some door holes that were bondo filled by PO) and clean them. I almost always drill holes out to one size larger with a step bit to clean out the inside of the hole as well as give a round hole to fill. Then I make sure the area around the hole to fill is smooth and not needing hammer and dolly work first. Once the metal is good then I cut pieces of sheet metal to fill the hole and tack them in. Then tack them all the way around to form a complete weld, but do not weld it all at once because you will cause warpage. Then grind them down and prime. Then when you are ready for body work they may take just a bit of filler to smooth things out and you are done.

Kevin