Ideas for patching these holes?

[Americanvanlife]

I want it to be flush that’s where my main concern is coming in. Was hoping to use panel adhesive but is welding going to be my only option?

 

[highdesertranger]

if you want it to look like they were never there, then a lot of work is involved including welding. highdesertranger

 

[Spaceman Spiff]

Proper way to fix: welding a patch in followed by bodywork and painting.  Should be invisible.
Next best: screw and caulk a metal patch over the holes.  Obvious but flush with side of van.
Almost as good: metal patch held on by VHB tape or caulk.  Again, obvious.
Ghetto: patch taped on with ductape.  Won't last long; need to replace frequently.  Might not stay watertight.

 

[Americanvanlife]

I cross posted this and got a brilliant answer that I’m very excited to try out and figured I’d share so if anyone in the future runs across this post. I’m going to buy an air crimper tomorrow and make a flange all around the outside of the hole, then get my sheet metal cut out .5-1” larger then the original hole so I can seat it in flush then use 3M panel adhesive on the seals. There may be a faint line you can see I’m guessing but to get the auto body shop to do it and weld it would be at least $1500 compared to the $350 this will cost and I’m thinking it will look really nice. Will know by the end of next week.

 

[Groovy2]

yup glue it -

RC Hobby stores sell 15 minutes epoxy -
works good -
will never come off -

 

[Beeps and eats]

Use a body flange tool it will run a recessed bead around the opening that you can fit a piece of sheet metal into then if you can get a mig welder lay a bead around it by doing just a 1/4" at a time to prevent warping. Once welded grind it slowly again to prevent warping. And then primer and paint.

Sent from my Z981 using Tapatalk

 

[JeffJones]

Any follow up? How did it turn out? I may do something like that.