Need advice filling 1/2" holes in a pickup body.

[sixdogs]

Below is a Dodge dually pickup bed with the fenders removed. I'm going to use it without them.

After removing the fenders, I'm left with maybe 25 half-inch diameter holes in the body. They are all the same size and I need to weld them shut somehow. I'm probably not capable of the weld but I need the repair to stay stuck so it doesn't mess up the nice paint job it's going to get. How would these be welded? Note that a few are not accessible from behind.

Any advice appreciated.

 

[Shield Arc]

I'd take a hole saw cut some plugs the same thickness as the bed. Place a piece of copper behind the ones you can. Use some .023 Mig wire to weld them up.

 

[bcp]

Fill them with 1/2 inch bolts. It will make your truck look "manly."



Bruce

 

[sixdogs]

Fill them with 1/2 inch bolts. It will make your truck look "manly."



Bruce

It's going to be a two ton pickup. It would look many in a pink party dress.

I'd take a hole saw cut some plugs the same thickness as the bed. Place a piece of copper behind the ones you can. Use some .023 Mig wire to weld them up.

Shield Arc..if the holes are half inch, what diameter would the plugs be? Would a metal fab shop have some easy way to punch out 25 of them?
If I were to weld them in myself, would I weld in short lengths and let cool to prevent distortion? Thank you.

 

[Shield Arc]

It's possible a fab shop will have a hydraulic iron worker to punch out the plugs for you. What I'd do is run down to Lowes or Home Depot or hardware store and measure the inside of their hole saws. Buy the correct size. I don't do body work, but have seen it done. Make four tacks, north, south, east, west. Something that small you might as well just fill in the rest with tacks. If you have a chunk of copper or aluminum to put on the backside that will be a heat sink, which will help with distortion. Don't be afraid to make a few tacks, and move to another location, too much heat will make a big mess of this!

 

[weldermike]

You could get a bunch of 2in squares, stack em and tack em to hold them together on the sides, and wholesaw out a whole pile of them in one shot.

 

[Shield Arc]

If you decide to use a hole saw, instead of using the pilot bit. Use the hole saw to drill a hole in a piece of plywood. Use the plywood as a keeper on the metal so the hole saw doesn't wonder all over. If you use the pilot bit, it's just another hole to fill.

 

[sixdogs]

Wow, thanks for the help. Some great guys here.

 

[k0ua]

Chuck your holesaw up in your drillpress, NOT your hand drill. Much more stable.

 

[Dr Dave]

Are you going to patch the cutout above the wheel opening? Or install flares? I like your portable work platform:thumbsup:

Dave