When you click on links to various merchants on this site and make a purchase, this can result in this site earning a commission. Affiliate programs and affiliations include, but are not limited to, the eBay Partner Network.
Here's a thought: get a welder that will serve this purpose, as well as future projects. If you do that, you won't be disappointed.
As for the frame that you are working with, welding up for cosmetics is fine, but here's what I would do. Cut a piece of metal to fit the hole you are trying to plug. Tack it in, and then "make it pretty" with a little body filler. Sand it down (grind the welds) and then paint it. Either way you are going to have to grind your welds, but a tack is easier to grind down and make pretty than a complete hole filled with weld. I've seen the holes you have to plug, as I have had two 77 trucks. Have fun, and post pics.
I have Ford data sheets that show up until 1990 Ford frames were made with 35k psi steel and not high strength steel. The strength increase comes from a taller cross section. Maybe F-350s were different then E series, F series, and BIIs? Having drilled many Ford frames I think the Ford data is correct.
I have a Hobart 135 and using flux core .030 it does fine for welding up truck frames and bumpers.
Rezvani's Latest Post-Apocalyptic Monster Is a Ford F-150 Raptor Underneath
Slideshow: Called the Fortress, the 850-horsepower pickup combines Raptor underpinnings with military-inspired features, survival equipment, and a starting price of $285,000.