Repairing rust hole

[alexander]

hi windex,
odd place to get a rust hole! is there something else going on in the area that might need attention?

anyhow, i agree with the others. it doesnt sound like a structural issue, nor one that even the nosiest pink slip inspector could ever see, so the easiest thing is just to rivet/bolt a plate over it, and i agree about the sikaflex too.

if you do want to weld, i can confirm that it is easy to make a big mess of holes with a stick welder on even robust sheet steel! a mig would be highly desirable. if you go that route, you want to tack the plate in a couple of spots, then move slowly along the edge, making a series of single, overlapping spot welds. ie just trigger on, and almost straight off. they join up into an (almost) seamless weld, and you dont burn through. then seam seal and paint from underneath, as far as is possible. or fish oil. or even some grease up underneath. anything that will keep water out of the seam.

gas if fine too, but if you have ever tried lap welding sheet steel, you will find it is surprisingly tricky. the two surfaces have to be very close together, or the top layer melts back. trying to keep a patch hard down on a curve transmission tunnel could be quite frustrating. if you go this route, brazing would be preferable, and effectively as strong.

regards
alexander.

[2JeepFamily]

Everyone has given good idea's somy recommendation is if it is a rust hole make sure you cut it out fresh metal then coat with rust inhibbitor and paint
over it to stop the rust from spreading
When lapping welded steel best bet is start at corner and weld it in place. Then while the metal is still hot it will be easy to bend and manipulate to the shape that you need bit by bit. My choice would be MIG weld or rivets

[Windex]

Believe it or not I wouldent be all that worried about it but it got picked up during a RWC(pink slip inspection) and I need to fix it.

[2JeepFamily]

Originally Posted by Windex

Believe it or not I wouldent be all that worried about it but it got picked up during a RWC(pink slip inspection) and I need to fix it.

Thats must be one picky inspector. Another idea is if you don't need structural soundness, is just fiberglass putty will fill the hole be neat and
quick.

[Gildo]

Nope cant fix that you'll need to replace the entire body shell.....

How big is this hole? Can you just stick a bolt through it and plug it?

BTW, due to the way these bodies are constructed, without a seperate chassis, I'd think that every part should be considered structural. Transmission tunnel is like a torsion member for the centre of the floor pan.
Every bend and ripple is there for a reason.