I have a 1976 Ford Truck, 4x4,
The rear bed panel are rusted thru, just above the rear tires.

Tool I have to do the job. cut out tool, air compressor, 4 inch disk grinder, mig welder, rivet gun, different grit of sand paper, and spray gun.

Question #1,What is the process for repairing this panel? I have never done this type of repair, but I am eager to learn and do the repairs myself.

Question #2, I need to cover up some old screw holes on the door panels, The previous owner had used different mirrors and put holes on the door panel I need to cover up. What is the process of welding the holes up with either a mig or an acetyline torch?

Buck

 

I would recommend ordering a patch panel...I have to do the same thing to mine. Use the patch panel to scribe a line to remove the rusted section. Then using your 4" disc grinder with a metal cut off wheel cut INSIDE the scribe line, because if you cut the line of the outside of the line, the thickness of your cut off wheel will make a large gap when you go to weld up. Next...make sure all paint is removed on all edges of the patch panel and the truck. Next butt up the panels, and take time to make any minor adjustments to fit. Once you are happy with the fit...tack weld all four corners with your mig..preferably .023 wire with co2/argon mix. Proceed around the panel making alternating tacks giving the panel time to cool to prevent warpage. All you are doing is making a bunch of tack welds that join together to make a solid weld. You are only on the trigger for a sec at a time. After that, hit with a flap disc...80 grit or so on your 4" to blend in the weld. If done correctly you will hardly notice, if at all where the weld was made. After that...standard bodywork of primer and filler, and sand.
Question #2. I use my mig welder to again make a quick tack on the side of the hole, after removing all of the paint around the hole. After making the initial tack...I continue tacking onto that tack until the hole is completely filled. Again, use a 80 grit flap disc and grind smooth. Always be careful with grinding as well as you can generate alot of heat which could also warp the metal. Let the disc do the work and do not apply much pressure to reduce heat. Hope this will help.