A picture says a thousand words... I'm looking for advice on how to patch this rust above my passenger side door. I have access to a mig welder but I'm pretty sure I'd blow right through that thin metal if I tried. My other thought is cutting it out and patching it with fiberglass. Anyone else deal with this specific problem spot? Thanks y'all

 

It's not hard to weld sheetmetal. Practice on some scrap sheetmetal the same thickness. Watch youtube videos. I wouldn't fiberglass it.

 

Thanks, If I had a garage I could pull my truck into I'd TIG weld some sheet metal on there. Since I don't my only option would be to fluxcore MIG weld it out in my driveway. I'm comfortable doing that on the bumper I built, and the rust on the bed where the metal is a little thicker but this is just too risky. The hole is about an inch or two away from the insulation on the roof of my cab. I'd be pretty bummed if that melted or caught fire. I'll ask some welder friends what they think but the point of my post is to explore options other than welding. Any ideas?

 

It is my opinion that anything other than cutting out the rust and welding in new metal is going to be straight hack work. You can remove the headliner and weld it with a mig. Use thin wire and gas, not flux core. You can also plate the backside of the repair to make burning through less likely. If doing this yourself isnt an option I'd suggest looking into paying someone who can. Rust sucks. Good luck.

 

Flux core welding isn't the best, I wouldn't use flux core. Pay someone to weld in new metal, then finish it yourself.

 

A good welder can make this repair look easy....I agree that this may not be the place to repair yourself if you don't weld a lot.

I would repair with the POR15 floor pan repair kit before I used fiberglass....but it will always looks like a patch job.

 

Wire brush the rusty spot. Punch out the rust in the middle of the hole. Spray ospho like a mad man into the hole in both directions. Push steel wool into the hole tightly. Slowly pour molten lead over the steel wool letting the lead fill the hole and smooth it out with the equivalent of a metal popsicle stick.