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When I am wleding in patch panels that are closed from the back would I be best to use stainless steel to prevent corrosion.
If it's not in too obvious of a place on the truck, you could glue on the panel, therefore never adding heat or leaving bare metal behind. Hopefully Cujo jumps in here and posts some of his pictures on this approach. He really did i nice job in a similar situation.
John, here's the thread that Duke78 is referring to where I used 3M panel adhesive to attach new cab corners on my 77 F150. In doing it this way I was able to fully protect the inner metal with primer, paint, and seam sealer before I glued in the cab corners. According to 3M's website this adhesive is supposed to be 11 times stronger than welding and there's no heat to warp your panels. I did this repair while the cab was off the truck and a week later 4 of us lifted the cab and placed it back on the frame and the 2 guys that were lifting the cab from the rear were using the repaired cab corners as a handle. I'm very pleased with how it all turned out and the funny thing is the person who turned me onto this panel adhesive is a welder by trade and he swears by it.
You can get it at your local paint shop probably, i just bought a tube of 3M Duramix... If you can't find it loacally then you can order it online... Their are tons of places on the net that will ship it right to your door. Do a search.
Most body shops have gone to using the 3M panel adhesive. It is much stronger than welding, and the repaired panel seems to hold up to the elements a lot better. Most of the time welded patch panels will only last for a couple of years before moisture works its way into the weld seams, causing little bubbles in the paint.
If the welds, after being ground almost completely off, are treated with fiberglass reinforced body filler, they will be a permanent repair. I only posted this to be clear. My intention is not to discourage the PROPER use of sealant.
As with anything else, preparation is everything. Follow the adhesive instructions carefully if you plan to attempt its use.