Swiss Cheese Rust

The passenger outer rocker had a lot of rust holes. Almost like swiss cheese. The panel it self was in good structural shape. it would have been a lot of work to cut and weld so many smaller patches. I decided to fill these holes with the mig welder. On the right side of the image you can see i already filled some holes.

After a little wire wheeling.

As a backing i used the a copper ‘welding helper spatula spoon’┬áthingumabob. Steel weld does not stick to the copper so the spoon comes right off. After a little grinder the final result was to my satisfaction. i held the spoon on the outside of the rocker and welded from the inside. i only need to grind down the outside since the inside will no longer be visible once the floor and inside rockers go back in.

holes filled and finished off with sandpaper flap disk on grinder.

the two holes on the left were too big. had to fill with a metal patch.

End result. almost perfect but once some primer goes on and a little filler to cover. the work will not be noticeable.

i am not sure how ‘correct’ this type of repair is as i have not seen it done or discussed in the forums. But i like it!

One thought on “Swiss Cheese Rust

  1. Hey bro I am in the process of bonbibg my flh . I am looking for a wide girder fork to complete the ol skool look . This would be a stock to maybe 3 over fork . I would also like a single disc mount . no fender tabs . Looks like you have what Im looking for and looking to get a ball park price , thanks looking forward to working with you on this project .

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