How best to fix this?

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I noticed the other day that one of the rear hatch struts on my wife's Honda Pilot was loose.  I snugged it up at the top, but then noticed that the sheet metal somehow got torn at the bottom.I think maybe I can take out the strut bolt & push the broken flap back into place from the inside & either weld or braze it, but if I can't I'll have to weld or braze on a reinforcement plate of some sort to spread the load.  I'm not quite sure how the damage occurred - it may have been like that for years & I never noticed.View for contextCloser views
Reply:Interesting.The area around the strut stud location looks like it has a doubler around it. It looks like a failed spot weld.Does the hole,/crack extend all the way to the stud location, it looks like it stops short. I was wondering if it was in an accident in the past. Maybe the spot weld got pulled when the right rear quarter was hit or something. I can't see it being directly related to the lift strut.Clean the paint off and weld with whatever process you have. Mig would be my first choice. Maybe drill a small hole in the center of the flap and pull it back flush first, then fill that hole in as well.
Reply:Remove the strut clean, weld and paint the bad spot. Then install a New pair of struts as those are going bad.www.georgesplasmacuttershop.comPlasma Cutter and Welder Sales and Repairs--Ebay storeTec.Mo. Dealer Consumables for the PT and IPT torch's
Reply:Remove the strut from the ball....take out taillight....push the u shaped part flush ...sand to bare metal ....tack it closed.....grind it smooth...rattle can prime and paint....also the ball pivot will probably turn out to make the repair easier
Reply:Originally Posted by mechanic416Remove the strut clean, weld and paint the bad spot. Then install a New pair of struts as those are going bad.
Reply:I wouldn't fix it, unless it was causing a problem. It doesn't look to be cracking up to the strut mount, or causing any undue trouble/ Looks like something may have been in the doorway when the hatch was slammed shut. It is your wifes car, so you will likely never know what it was.
Reply:"when struts fail,they get weaker,not stiffer. why tell someone to spend a lot of money for no good reason"Apparently some people don't know what they are talking about. I have replaced a lot of struts that were getting very hard to close or locked in the open position.www.georgesplasmacuttershop.comPlasma Cutter and Welder Sales and Repairs--Ebay storeTec.Mo. Dealer Consumables for the PT and IPT torch's
Reply:Being a bodyman, unless it is a new vehicle and bothering you I would advise you to put some type of sealer you have laying around or even a piece of duct tape and leave it alone.But if it is bothering you their is potential for water to access the hole create rust and for the hole to further open it it has to be cleaned welded wash primed then paint blended in.Preferably welded with tig, as mig has a tendency to pit as most migs don't have post flow and you will be trying to control heat.Also is your shock leaking abit?Or is the oil from the ball.
Reply:leave it aloneWelding/Fab Pics: www.UtahWeld.com
Reply:I'd clean it, tape it off and apply some bondo into the hole.  Then hit with touch up paint.  If you try to weld it, the paints gonna burn and be an issue.TA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:Originally Posted by mechanic416"when struts fail,they get weaker,not stiffer. why tell someone to spend a lot of money for no good reason"Apparently some people don't know what they are talking about. I have replaced a lot of struts that were getting very hard to close or locked in the open position.
Reply:Looks to me like the strut was replaced once and the old one was detached at the top levered against the body panel to remove the bottomMillerMatic 252, HTP 221 w/cooler, Hypertherm PM45, Lincoln IdealArc 250 AC/DC"I'd like to believe as many true things and as few false things as possible"
Reply:No worrys, Just fill with a glue/sealer preferably gray to match body color and forget about it.
Reply:If you don't feel comfortable welding it up as much as I hate the stuff JB Weld is an alternative.Every pontoon / houseboat repair I do takes me longer to clean that crap off then to do the actual repair.