I recently bought a 1989 F150 am starting a slow rebuild. Along with the requisite rust removal on the doors and bedsides, I also want to change the mirrors from the "howdy doody" aluminum ones to the paddle type used on 1992 to 1996 trucks. This poses my dilemma. There will be holes left open on the doors. I've never done any welding or body work beyond spray paint, and I am planning on getting a small MIG welder soon. Does anyone have an opinion or advice as to whether or not I'll be able to effectively fill, grind and hide theses holes?

Thanks,
Mike:-X23

 

You should be able to slide small "patches" from the inside of the door and cover the holes. Tack them from outside of the door,grind and fill. No need to "fill" the holes with weld, you will most likely warp the metal if you try.

 

When I weld small holes with my MIG, I use an old sledge hammer head on the back side. It acts as a heat sink, so the metal doesn't get too hot and warp. I've heard that a big chunk of brass works even better. A few times, I got my patch too hot and the hammer head almost stuck. Brass wouldn't.