Originally Posted by Trask97140
My process was angle grinder for cleaning/scarring surface. Wiped with acetone to further clean. Applied a 2 part epoxy around the hole, then caped it with little 1"x 1" metal cutout. On the smaller holes I just used epoxy.
Plan on covering/Insulating the floor down the road. So the little metal cutouts wont even be noticed.
I did this on my first bus.
This is the best overall method for durability and longevity short of welding.
The epoxy and metal patch method in some ways is better than welding. It is a complete bond between the two layers of metal. No gap for rust to get between and cause a issue.
Welding done wrong can also cause a porous mess on small holes, and runs the risk of warping the metal.
The use of flux core wire in a mig welder is a big no no. It causes nice little spots of impurity's in the weld, just welcoming new rust to start nearly immediately after the repair.