Hi,

At the moment my car is resting in the painters workshop. The car has been sandblasted, zink sprayed and got the 1st coat of 2K epoxy primer. Unfortunately there are 2 areas with holes in the body. My painter wants so seal/cover the holes using filler but I am not totally sure about this way forward. I need the best possible solution from a corrosion point of view and cannot accept bubbles in the paint after a few years because of a bad filler job.




How would you proceed in order to cover up these holes before proceeding with the paint job? Welding, brazing, soldering ... or some magic type of filler?

Thanks in advance,

Lucas

Sounds like you already know what happens when you just mudd over holes. They need to have the bad / pitted metal area cut out and solid metal patches welded in.

Your shop owner is a butcher. The last 5 restorations I've done were shipped to me because other shops or backyard experts did horrible workmanship and had pitiful knowledge. Yank the car and find another shop. If you are just building a beater and do not care about longevity, then pack the holes with filler.

When you say car had been Sand Blasted I hope they really didn't use real sand or play sand but another type of media Please Identify what was used?

When you say it was Zinc sprayed please identify what manufacturer & product that was used? I have been experimenting with a couple of these products myself.

Cutting out the Holes or Rusted panels and welding in Patches is the right way to do it.
While the Welding Technique used is Controversial I prefer Gas hammer welding or Tig welding myself. Then there is of course the Gluing method, I like Glues myself others cant stand the idea of using them they feel its not a true bond that can and will fail.
I feel that if they are used properly they are very suitable for some cosmetic repairs.

Doright wrote:........ Then there is of course the Gluing method, I like Glues myself others cant stand the idea of using them they feel its not a true bond that can and will fail.
I feel that if they are used properly they are very suitable for some cosmetic repairs.

Count me in on liking bonding. It's as strong or stronger than welding, and the panel dosen't rust from behind as quickly (as from welding). The patch has to be flanged for a good fit.

Dennis, I'll bet you've bonded lots of aircraft skins...

I have fixed a lot of acft over the years, I didn't intend to bring up the adhesive issue.
I myself like the stuff and Trust it when its used properly.

Still it doesn't compare to a Properly performed Hammer weld.
https://www.youtube.com/watch?v=Rv5bKXJ3kEM&t=19s