Termites eating my woodie

[mrtexas]

I found some rust on my 49 woodie tailgate. I submersed it in ospho to remove and stop the rust but now have some holes. I'm not up to replacing all the metal. I've considered the following:

Dab JB weld on the back side of the rust thru, bondo, and paint
Tack in sheet metal behind the rust thru, bondo and paint

Any thoughts on what to do?

[ford38v8]

Just my opinion, but anything short of a first class repair will devalue your woodie, if only in your own mind. You've got all winter to git er dun.

[19Fordy]

Gee Whillikers! A 49 woody is too nice a car to cut corners on. Is there noone in your area who could repair it for you at a fair price?

[Graeme / New Zealand]

As they say do it once, do it right. 49 woodys are cool.

GB

[rotorwrench]

That can be piece meal patched without too much problem. A fellow model A guy that restored a few used to just cut out the hole until he would get to thick enough metal to get a good weld to. He would make a pencil pattern of the hole and fabricate a piece of metal to fit of the same gauge thickness. Using magnets to hold it he would tack it in then weld systematically little bits at a time to prevent warpage. It took a while since he used an oxy/acetylene rig with an aircraft torch but it always came out to where he only had to use a little hammer & dolly work plus some body filing to make it look like new. The edges that have the bend lines are structurally strong and can take some pretty good heat without problems. Now out in the middle of a panel, it takes a little more finesse and care since there is no support and it warps easily.

If you do decide to use filler of some type to plug the holes, make certain you put some very good corrosion resistant epoxy primer on there and sand that for a good stick or it will debond with more corrosion later.

[mrtexas]

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I'll probably end up cutting out rust, tacking in a backing plate behind and then stitching in some new metal on most of it.

[deuce_roadster]

I'm with rotorwrench, cut out the metal, fairly simple shape to fabricate, fit up as tight as possible and if you have a friend who can come and TIG weld it you shouldn't have to use much if any filler, probably just hi build primer. If you can't TIG it then take your time and gas weld it or wire weld it with easygrind wire. This isn't a huge deal.
If you do go the easy route, use AllMetal instead of normal plastic filler, it is much stronger.

[Dave/Green Bay]

Is there anyone near you that still does leading. After the metal patch it's much better than plastic filler. Dave/Green Bay

[woodiewagon46]

Please no JB Weld or Bondo, it looks like a fairly simple repair so do it right and you won't regret it.

[V12Bill]

MIG or TIG in patches, grind off excess weld, level with quality body filler and the job should last a life time. Did this with a VERY rusty Zephyr 15 years ago and the job is still holding up

[bobpo1]

Do it right and you'll never regret it...

[mrtexas]

Here is my first try at the holes. I used a backer of 16gauge sheet metal. Worked great.
Thanks for the encouragement.

[rotorwrench]

Workin like a champ! Keep up the good work.

[mrtexas]

I backed up all the places I could with 16 gauge sheet metal. The rest I gobbed on some weld and then closed up the holes.

It's got pimples now!

[19Fordy]

Good job. You should feel proud ( a little).

[flatmotor40]

Use can use a back up of copper and the weld will work better and the copper will not stick and cause more areas to hold moisture

[Sixseven]

Originally Posted by flatmotor40

Use can use a back up of copper and the weld will work better and the copper will not stick and cause more areas to hold moisture

Wow, first time I've heard this trick - I like it.

[Tony, NY]

Originally Posted by Sixseven

Wow, first time I've heard this trick - I like it.

http://www.eastwood.com/welders-help...&parent_id=896

[deuce_roadster]

You can take a piece of copper tubing put it in a press and squish one end and you have a backup that works on medium sized holes and has a handle as a bonus. That is what I use.

[Ronnie]

Aluminum strip works well also and easier to obtain than copper. 1/8"

R