I have a 1970 Monte Carlo and around the rear window it is rusted like all of this times cars. On the passangers lower corner where it curves around there is a hole in the metal it is like a half moon shaped hole right in the middle of the curve what would you suggest to fix it should i just fill it with filler if so what kind of filler it is on the verticle part not the flat part the window sits on it is about 1 inch long thanks for any help you can give

Cut that area out and fab a piece to replace it with, have it welded in solid. Never fill holes with filler if you want the repair to last.

Just curious,do you have the window out and are sure that's it? Poked around the rest of the opening? That's a big hole and would be unusual not to have more damage. Years ago I had a 71 Monte SS454 that needed major repairs around the window. Pretty much a cut and fit,weld and grind job. I've done a lot of these;most folks hate doing it or can't do it. Does'nt really bother me.

If you dont have acesss to a welder or know someone who does, then you can use POR-15 on that area (follow their prep directions) and after a couple of coats of POR-15 then use their POR-Epoxy Putty. This stuff is very strong and tuff and can be smoothed out when applying with a little water on your finger. GREAT STUFF ! It can be sawed,drilled etc. Ive used this product on several occasions and am very well pleased with the results. One of the places I used it was also on the rear windshied area of my Chevelle. And I do have a welder. Youd be lOOOOOONNNNNNNNNGGGG GONE before that stuff ever gave way. Prep the area,use the POR-15, after its dry use the POR-Epoxy Putty , then prime and paint and youll never have to worry about that area ever again. Mark

Rick M.
When you weld in a piece of sheetmetal, what settings do you have your midwelder on. My migwelder goes as low at 30 on the amp gauge, but even at that low setting, I blow through sheetmetal on occasion. I'm using .030 wire (I think), and my gas pressure is about 25 psi. What do you say is best?
Andrew Offutt

P.S. About the POR-15 with their epoxy, I agree that this is a good and permanent fix for small holes, but for anything bigger than a nickel, I think new metal is really the only sensible way to go.

Just learning about welding but try the .24 wire, more resistance, less current.

check out my site (in my sig) go to the 70 chevelle page for some pic of how I fixed this area.

Andrew,you need to useing .023 wire. Heat setting on my welder will be different than yours. Just enough for good penetration. It's not easy welding 18-20 ga steel. Too cold a setting is worse than too hot. Take your time! Bear in mind the spatter travels a long ways. Guy I know was having problems welding around his rear window and asked me to come take a look. Saw his quarter windows were rolled down and told him to roll them up. The weld splatter had ruined the windows. 100 black burn dots on both of them. Your gas pressure is a tad high,but okay. Some folks like POR and some do not. I am in the latter group. If I bought a classic car and found the prior owner used that stuff to fix a rust problem,would be PO'ed.