I posted this earlier in the tech area, but it probably belongs here...

I am in the stage of prepping the exterior of my 64 malibu, but really don't like the look of the beltline body moulding. I like the "clean" look. But, there are about 15 holes per side, oval shaped, approx 3/8" around where the moulding attaches that would need to be filled to accomplish this. Is there anything I can do at home, such as a cold weld epoxy material (like this -
http://www.por15.com/Default.aspx?TabId=87), or am I going to have to bite the bullit and tow the car (not currently roadworthy) to and from a welder? Any idea what this might cost? And third, do I run a risk of warping the panels and really messing thing up? any feedback or suggestions would really be appreciated! Thanks!

Weld-n-grind..

Too big to fill and sand?

Weld and grind. 3/8" is to big to bondo up. You could push the bondo right back through the hole after it has been finished. Use a back up bar of copper or aluminum when welding these up and expect warping of the panel unless your real good at this.

A 3/8 hole would be easier to weld up if you made a "plug" and welded that into the hole vs just trying to weld up that hole.

Basically make a disc just a tad smaller then 3/8 and weld it inside the hole.

I would take a uni-bit and enlarge those holes to one constant size hole. That way you dont have holes in three or so different sizes. Just make one sized "plug" for your holes.
If you are MIG welding I would NOT try to weld that hole shut in one pass. Make a weld the size of a tack weld. Allow it to cool, make another small weld.

What ever you do DO NOT cool your welds with water or air!!!!
Cooling them will shrink that metal causing your warpage. If you allow that metal to cool on its own terms the warpage will be far less then forcing with air or water...Eric

http://www.htpweld.com/products/accessories/a6.html#HTP%20Heat%20Sponge

ive used stuff that was supposed to do what this stuff actually does, i highly recommend it, especially if youre nervous welding panels

i should add that all the HTP products ive tried are top quality

srape any body schutz, undercoating, and paint from the backside of the hole and have a helper wearing gloves hold a copper backing over the hole from the inside. MigWeld the hole shut from the outside. They will weld up easily, the copper pulls the heat away minimizing warpage.

I seen a friend weld up trim holes on his 64 Chevelle SS with clothes hanger filler rod and an oxy/acetlyne torch and ruined his car.

ouch bob,... i guess you saw it after the fact, i was wondering why you didnt thump him on the melon, hoping he'd see the light