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Old 12-02-2005, 09:09 AM
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Question for metalworking guys

When I learn about something new, I tend to mentally try to apply it to things I see.

Lately I've been thinking a lot about the bondo-less metalworking techniques discussed at length on the board.

Last night, I was looking at my truck (2000 Sierra). I noticed there is a welded seam where the back section of the cab, behind the door is attached to the door sill/rocker panel.

Was thinking that, if I were ever to paint the truck, I'd want to fill that seam in. Its a shallow line about 3/8" wide and maybe 1/8" or 1/16" deep.

In the past, I would have just spread a little bondo over it and been done.

Now I'm wondering how I would handle it without bondo.

Best thing I can come up with is to fit and weld a thin strip of metal over the gap, but I'm wondering if that's the best solution. Perhaps filling the area with weld and grinding it down?

What would be the best (hypothetical) way to handle this?
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