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

[Jesse masterson]

be very picky when filling rust holes, many times you can think you have the rust hole the proper size to get rid of the cancer and find out later the prpblem was a lot bigger, cant see underneath and can't take a caliper to measure how thick the metal is 6 or 8 inches from the hole, I've restored several vehicles 71 rt charger, 66 jeep j200, 78 jeep, to start . And I dicovered rust can be very unforgiving . I would cut the whole area out several inches around whole and put a whole new piece in. Just me!!!

 

[sixdogs]

They are not rust hole at all but rather factory drilled holes used to mount the dually fenders. I removed those fenders and am going to fill the holes. There is zero rust.

be very picky when filling rust holes, many times you can think you have the rust hole the proper size to get rid of the cancer and find out later the prpblem was a lot bigger, cant see underneath and can't take a caliper to measure how thick the metal is 6 or 8 inches from the hole, I've restored several vehicles 71 rt charger, 66 jeep j200, 78 jeep, to start . And I dicovered rust can be very unforgiving . I would cut the whole area out several inches around whole and put a whole new piece in. Just me!!!

 

[Oldpath05]

Best way to fill in 1/2 to 1" on truck frame or any kind of steel project, is use flat ceramic, come's in 2' strips in all shapes and sizes, has aluminum tape on one side so it can be taped to the steel, and you can weld on it from one side, if done right, the weld come's out smooth on the back side with no void's, and the ceramic just knock's rite off. This stuff is used by the tons in shipyards to weld 2 plate's of steel together with a root opening of 1/8 to 2" and get 100% weld. I'm sure most welding store's sell's it.