Worked on the Boss's 64 LWB - The 1947 - Present Chevrolet & GMC Truck Message Board Network

Rokcrln · 03-04-2006, 10:50 PM

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

Rokcrln · 03-04-2006, 10:51 PM

And some more!

Rokcrln · 03-04-2006, 10:53 PM

And

Rokcrln · 03-04-2006, 10:55 PM

Last two. This truck is in great shape. It has just a small amount of rust on both front lower fenders and a bit on the bottom front of each door.

Kevin

Woogeroo · 03-05-2006, 04:33 AM

Thanks for taking and posting all the pics.

I often thought that was the best way to fill in a hole like that, but I'm no welder or body worker person.

-W

SIR · 03-05-2006, 03:25 PM

...It's great to see things done right..nothing worse than cleaning up someones elses "handywork" ..what's the plan for that truck??good base to work on....

coilspring66 · 03-07-2006, 12:35 AM

Nice pics! I did mine a little different. I took a screw & tapped it in the hole until it was secure & tight (not too far in, mind you) & then cut off the part that was protruding (including the screw head of course) flush with the sheet metal. I then tacked it so it wouldn't move over time. The nice part of this method is that there are no gaps (which means less welding & filling) & less of a chance that the filler piece will drop inside the door (if you're clumsy like me).

03-04-2006, 10:50 PM	#1
Rokcrln Senior Member Join Date: Jul 2005 Location: Winters Ca. 95694 Posts: 4,843	Worked on the Boss's 64 LWB 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 Attached Images Last edited by Rokcrln; 03-04-2006 at 10:57 PM.

03-04-2006, 10:51 PM	#2
Rokcrln Senior Member Join Date: Jul 2005 Location: Winters Ca. 95694 Posts: 4,843	Re: Worked on the Boss's 64 LWB And some more! Attached Images

03-04-2006, 10:53 PM	#3
Rokcrln Senior Member Join Date: Jul 2005 Location: Winters Ca. 95694 Posts: 4,843	Re: Worked on the Boss's 64 LWB And Attached Images Last edited by Rokcrln; 03-04-2006 at 10:58 PM.

03-04-2006, 10:55 PM	#4
Rokcrln Senior Member Join Date: Jul 2005 Location: Winters Ca. 95694 Posts: 4,843	Re: Worked on the Boss's 64 LWB Last two. This truck is in great shape. It has just a small amount of rust on both front lower fenders and a bit on the bottom front of each door. Kevin Attached Images

03-05-2006, 04:33 AM	#5
Woogeroo Registered User Join Date: Aug 2003 Location: tool box Posts: 3,115	Re: Worked on the Boss's 64 LWB Thanks for taking and posting all the pics. I often thought that was the best way to fill in a hole like that, but I'm no welder or body worker person. -W

03-05-2006, 03:25 PM	#6
SIR SIR Join Date: Apr 2005 Location: grants pass oregon,usa Posts: 658	Re: Worked on the Boss's 64 LWB *...It's great to see things done right..nothing worse than cleaning up someones elses "handywork" ..what's the plan for that truck??good base to work on....* __________________ 66long low fleet http://community.webshots.com/user/LVNR66 Last edited by SIR; 12-08-2006 at 02:54 PM.

03-07-2006, 12:35 AM	#7
coilspring66 Registered User Join Date: Nov 2004 Posts: 31	Re: Worked on the Boss's 64 LWB Nice pics! I did mine a little different. I took a screw & tapped it in the hole until it was secure & tight (not too far in, mind you) & then cut off the part that was protruding (including the screw head of course) flush with the sheet metal. I then tacked it so it wouldn't move over time. The nice part of this method is that there are no gaps (which means less welding & filling) & less of a chance that the filler piece will drop inside the door (if you're clumsy like me).



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