Filling Holes on doors from trim mldg, too be painted

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Filling Holes on doors from trim mldg, to be painted

My situation: Recently had a lady crash into the rt side of my white(code 045) 91 FJ80.

lc02k.jpg


Looked tirelessly for another white donor vehicle to no avail.
So I ended up getting both RH doors from mudder, lostit this past weekend (thanks!).
His 80 was a dark green '97 40th Anniversary Edition with the narrow side mouldings.
Looks like I'll have 2 (smaller than expected, like an eraserhead diameter) holes on each door to fill.

Not stressing too much over the holes, but since i don't have any welding equipment I was hoping for some ideas on how to fill them w/o them falling out from frequent door use?

I 'm considering one of the following, feel free to chime-in with other feasible suggestions.

1. JB Weld a small metal backing plate behind the hole, let cure, fill with polyester filler like techniglaze(last filler product I used).

2. Use a fiberglass backing like above and fill with filler.

3. Brazing in a softer metal like brass to fill the hole and skim with filler.

4. just fill in the holes with filler and hope for the best.

5. white plastic plugs!

Like I said before, I'm not stressing over the holes. I'm more concerned with shooting the paint and messing with all the door jambs.
I've never used HVLP guns before, still have the old school devilbiss siphon guns that I grew to hate.
So I'll be having to get some new budget hvlp guns to do this and will prolly come back here asking more stupid questions for help. :hillbilly:
thanks!
 
Last edited:
the correct method would be to use a mig welder & weld them up using brass or alum. as a backer. the backer also acts as a heat sink to help keep heat out of the surrounding panel. grind the weld, prime, block, prime again if needed, & paint. if u have no tools, u can grind around the hole then tap the hole in a little so it's below the surface of the panel. then u can fill it with a long strand fiberglass filler, followed by a skim coat of filler, block,prime,block,prime again if needed, & paint. although this will probably last for at least as long as u own it, i don't recommend it because i'm a PROFESSIONAL. LOL
 
the correct method would be to use a mig welder & weld them up using brass or alum. as a backer. the backer also acts as a heat sink to help keep heat out of the surrounding panel. grind the weld, prime, block, prime again if needed, & paint. if u have no tools, u can grind around the hole then tap the hole in a little so it's below the surface of the panel. then u can fill it with a long strand fiberglass filler, followed by a skim coat of filler, block,prime,block,prime again if needed, & paint. although this will probably last for at least as long as u own it, i don't recommend it because i'm a PROFESSIONAL. LOL

Thanks MD. Wasn't aware of the brass or aluminum backer when welding.
 

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