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Youch. Check the inside of that frame rail for integrity. Cut out a nice regualr shape there and patch away. Don't see why you would need to double it up as long as you have the correct, or heavier, sheet though.

Never patch over the hole. Cut out all traces of rust, and then weld in a properly shaped patch. That area of the car is critical for strength, if you have any doubts about your ability to do it right, pay someone to do it for you.

Yeah, I was planing on cutting out all the rust. Then mig welding in a patch.The rail looks fine on the inside, no rust. It seems that it came with a renforcement patch from the factory?Thanks guys.

Yes, there was a doubler to stiffen up the frame box aft of the tension rod fitting. It was only spot welded in and not sealed so it collected water and rusted out over time. See the pictures on this post.

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Here is the damaged area cut out, a pattern cut and the repair piece ready to be welded back. Yes, I did match the doubler on the repair piece. The piece fits to the top of the inner frame rail on the opposite side of the fender and welds to the frame box all way around.

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  • 1 year later...
Can someone tell me if cleaning then welding a double patch over this rust hole (in picture) is OK? If so ,any pictures of same repair job anywhere?:stupid:

My passenger side was worse than that. I fixed it with minimal effort and made it stronger at the same time. (see my pics).

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