Small rust holes, weld or bondo - The 1947 - Present Chevrolet & GMC Truck Message Board Network

RodC · 10-09-2002, 12:52 PM

On the sides of my stepside, where the fenders meet the bed, there are small rust holes. after I remove the "bad" metal I am left with a hole about 1 1/2" by 2". Should I go ahead and weld
these up? Or get out the old bondo.

Its in small square patches where the lip of the fender met the bedside so I didnt really have to remove that much before I hit good solid, still holding orig paint metal.

I'm leaning twards welding, just wanted to know what the pros do for small holes.

Smooth68 · 10-09-2002, 01:19 PM

WELD - Definitely weld. I wouldn't take any chances with Bondo cracking loose later.

71402BB · 10-09-2002, 01:25 PM

I would have to agree! Welding is the ONLY way to go! I would cut a small piece of rust free sheetmetal, thats the exact size of your hole. Then very slowly tack weld it in place! Just becarefull not to warp the area your working on! Good luck! -Brian

RodC · 10-09-2002, 01:32 PM

Thats what I was thinkn. I just wanted to be reassured. Making a small patch to fit close enough to make a good butt weld is a PIA!

Any hints on butt welds appreciated. I have a lincoln weld pak 100 and I think Im going to try .030 flux core.

Better put on the asbestos undies, cause every one is going to say "use gas"

Burlinator · 10-09-2002, 02:19 PM

if you dont wanna make a patch to fit find a peice of aluminum big enough to cover the hole and start welding and the weld wont stick to the aluminum
you can also use the block as a doly to pound the welds down(hammer weld) so there is less to grind

crazy longhorn · 10-09-2002, 03:18 PM

"aspestos undies"....hehe! You can turn the heat down with gas, but i think its doable with flux core. I like to fit a but weld patch as tight as possible, then only weld a spot at a time...... & let it cool,dont get it too hot & you should be ok. good luck......longhorn

Mike C · 10-09-2002, 06:06 PM

Definitely weld to do it right. I bonded up some trim holes on the Jimmy 15 years ago and some are cracking but some are not. I was on a SERIOUS budget at the time. Since then, I bought a square chassis punch from Eastwood for doing small holes. It is MUCH easier to cut a square patch than a round one! I then use some Harbor Freight butt weld clamps to hold it in place to tack. Then pull the clamps and stitch it up! I like the flap discs you can buy for grinding the welds down.

RodC · 10-09-2002, 09:06 PM

I hope It will weld OK. I have welded 20ga with good results using .035 I hope with .030 it will even do better.

kaycee · 10-09-2002, 09:51 PM

Why don't u use the gas?I was welding without the gas for a long time finnally went and bought the conversion kit man what a difference that made

10-09-2002, 12:52 PM	#1
RodC Registered User Join Date: Nov 2001 Location: Fairmont WV Posts: 304	Small rust holes, weld or bondo On the sides of my stepside, where the fenders meet the bed, there are small rust holes. after I remove the "bad" metal I am left with a hole about 1 1/2" by 2". Should I go ahead and weld these up? Or get out the old bondo. Its in small square patches where the lip of the fender met the bedside so I didnt really have to remove that much before I hit good solid, still holding orig paint metal. I'm leaning twards welding, just wanted to know what the pros do for small holes. __________________ Rod Childers '71 C10 Stepside

10-09-2002, 01:19 PM	#2
Smooth68 Registered User Join Date: Aug 2001 Location: West Fork, Arkansas - Razorback Country Posts: 1,826	WELD - Definitely weld. I wouldn't take any chances with Bondo cracking loose later. __________________ Smooth68's Web Site WTB 64-66 project or frame/cab, SWB or LWB...I have the fever! Whatcha got?? '68 Short Step - Shaved Body, Soon Bagged - *SOLD* Driver-2004 GMC Z-71 Ext-cab

10-09-2002, 01:25 PM	#3
71402BB now thats a true COON DOG Join Date: Nov 2000 Location: Franconia, NH Posts: 1,977	I would have to agree! Welding is the ONLY way to go! I would cut a small piece of rust free sheetmetal, thats the exact size of your hole. Then very slowly tack weld it in place! Just becarefull not to warp the area your working on! Good luck! -Brian __________________ current project 67 402BB stout th350 3.08's with a locker. Plan on tubs 18.5's out back! (thanks Burnsman!) 71 SWB Stepside, was a 250, now is a 402 Big Block with 4 speed and 3.73's ( was crushed by a tree, bed sold, motor pulled) was my first truck!... oh well... 72 LWB 4x4 350 4-speed 3.08's posi wearing army olive drab green (SOLD!) 68 BURB 50TH LOOKALIKE work in progress, soon to have 250-I6 with a 3-speed on the tree 4.11's and posi ( currently sitting in back yard tarped awaiting time, $$$, and lots of love!) 67 1 TON- work truck 396 sm 420 4-speed, flat bed 4.57 gears "big red" (my first landscape truck, very rusty and crusty! but still gets the job done when needed!)

10-09-2002, 01:32 PM	#4
RodC Registered User Join Date: Nov 2001 Location: Fairmont WV Posts: 304	Thats what I was thinkn. I just wanted to be reassured. Making a small patch to fit close enough to make a good butt weld is a PIA! Any hints on butt welds appreciated. I have a lincoln weld pak 100 and I think Im going to try .030 flux core. Better put on the asbestos undies, cause every one is going to say "use gas" __________________ Rod Childers '71 C10 Stepside

10-09-2002, 02:19 PM	#5
Burlinator Just Another Crazy Canuck Join Date: Dec 2000 Location: Richmond,British Columbia Canada Posts: 1,228	if you dont wanna make a patch to fit find a peice of aluminum big enough to cover the hole and start welding and the weld wont stick to the aluminum you can also use the block as a doly to pound the welds down(hammer weld) so there is less to grind __________________ 1985 454/465/205, 38.5x11-16BOGGERS soon to be installed: 14bDETROIT,Edelbrock Performer cam,intake and valve springs,Comp roller tips,MSD HEI

10-09-2002, 03:18 PM	#6
crazy longhorn Fabricate till you "puke" Join Date: Jun 2002 Location: Ill Posts: 9,403	"aspestos undies"....hehe! You can turn the heat down with gas, but i think its doable with flux core. I like to fit a but weld patch as tight as possible, then only weld a spot at a time...... & let it cool,dont get it too hot & you should be ok. good luck......longhorn

10-09-2002, 06:06 PM	#7
Mike C Registered User Join Date: Dec 1999 Location: Austin, TX, USA Posts: 7,715	Definitely weld to do it right. I bonded up some trim holes on the Jimmy 15 years ago and some are cracking but some are not. I was on a SERIOUS budget at the time. Since then, I bought a square chassis punch from Eastwood for doing small holes. It is MUCH easier to cut a square patch than a round one! I then use some Harbor Freight butt weld clamps to hold it in place to tack. Then pull the clamps and stitch it up! I like the flap discs you can buy for grinding the welds down. __________________ 44 Willys MB 52 M38A1 64 Corvette Coupe 68 Camaro 'vert LT1 & TH700 69 Z/28 355 12.6's @110 69 Chevy Short Step 4 1/2"/7" drop 72 Jimmy 4WD 4spd 4" & 35's 02 GMC 2500HD 4x4 Duramax

10-09-2002, 09:06 PM	#8
RodC Registered User Join Date: Nov 2001 Location: Fairmont WV Posts: 304	I hope It will weld OK. I have welded 20ga with good results using .035 I hope with .030 it will even do better. __________________ Rod Childers '71 C10 Stepside

10-09-2002, 09:51 PM	#9
kaycee Registered User Join Date: Jan 2000 Location: Wyoming USA Posts: 2,445	Why don't u use the gas?I was welding without the gas for a long time finnally went and bought the conversion kit man what a difference that made __________________ 2001 Silverado K-1500 2005 FXDWG stage3 69 CHEVY Short/Step 327/4L60 373 posi 63 IMPALA 327



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