HOW I COVERED OVER 100 HOLES
1. Buy a small sheet of 20 or 22 gauge sheet metal. I bought a 1’x1’ piece at Home Depot.
2. Prep sheet metal - sand, clean, spray straight to metal primer, I also sprayed black rustoleum.
3. Mark and cut your pieces. I did 1”x1” little squares. 20/22 gauge is thin enough you can cut with sheers/ tin snips.
4. I had to hammer every little piece flat after I cut them because the small size and the sheers bend them a little.
5. Clean the inside of doors and fenders, front and rear. I used acetone to clean the areas.
6. Counted total holes on door number 1.
7. Lay out pieces needed for door number 1. I used a cooking sheet pan.
8. Mixed the two part epoxy on the same sheet pan. I used popsicle sticks to thoroughly stir the two parts.
9. Spread epoxy around the hole. Spread epoxy on backing piece. Press backing plate over hole.
10. Repeat step number 9 for the rest of the panels
*** take into consideration how much epoxy you mix at a time.
*** instructions say epoxy work time is 5 min but because I mix the two parts with the popsicle stick my work time was about 1 min.
*** I bought 3 different “caulking guns” for the two part epoxy and none of them worked. I ended up just pushing each part with a screwdriver. I would just make sure I would push out equal parts for both tubes. This worked out perfect as I was able to see and measure how much epoxy I used.
*** CAVEAT***
there are about 30-40 holes that you simply cannot reach from the inside to glue the patch panels.
My solution was to recut the small patch panels so they would have a better fit.
I then grabbed one of my body hammers and dented the holes just deep enough so that the metal patch panels were flat across the rest of the body panel.
I glued the smaller pieces straight over the holes. I then sanded everything smooth.
Finally I used body filler to fill any imperfections until the body panels were straight.
Below is the epoxy I used.