There are a lot of acrylic/methacrylate structural adhesives on the market that are perfect for what you want to do, you can just bond in a piece of scrap sheet metal behind each hole. Any structural adhesive is hundreds of times stronger than Bondo, and if you use the adhesive liberally it should fill most of what you need anyway, and alittle extra from the front will top it off.. Knock it down flat like you would with body filler, and you're done. There are a lot of vehicles that use this all the time. Elise chassis are bonded and riveted, and there are many vehicles that have body panels bonded on. You can do this for about 50 bucks ($15-20 for a small cartridge of adhesive, $20 for a cartridge gun, $5 for mixing nozzles, $5 shipping). I guess that would depend on how many holes you need to fill though..

That being said, if you can find someone to weld it for cheap, do it. Then you'll have a continuous piece of sheet metal, with no chance of thermal expansion cracking your paint at the seams, and you can't get better than that.

If you don't know me by now, I love alternative materials and new ways of doing things..

 

If you go the adhesive route Ive seen 3M's 8115 used which is a panel bonding adhesive. basically just bonding a piece of metal to the backside of the hole then using filler for the finishing part. I was actually surprised to look at it a month later and still not be able to tell where the hole was.

 

I would actually recommend against using a panel adhesive, they generally have some flexibility for thermal expansion. That's perfect for bonding a panel, but you really don't need it for a very small piece of metal, and the flexibility can get you in trouble. Go with an industrial adhesive, not an automotive adhesive for that reason. Check out McMaster Carr Supply if you want to bond this instead of weld it.

 

where can i get the industrial should i go that route?

 

See my above post. Like I said before though, I'd get it welded if you have the option.. If you haven't found anyone, you're either not looking or don't want to pay someone.

 

3M DP-810 acrylic (or 810NS; non-sagging). Easy to get, easy to use. 50mL cartridge, 10 minute work life, green or black, $12 each. $20-35 for the dispenser gun, depending on brand.

But I'd still weld it.

 

why do people remove the moldings? they are there for a reason.

 

Here's the car he's working on:

https://www.vadriven.com/forums/showthread.php?t=170135

 

the molding was already removed but filled in... if i didnt have to do this i wouldnt... TRUST ME .... ummm *sigh*

 

the molding was already removed but filled in... if i didnt have to do this i wouldnt... TRUST ME .... ummm *sigh*