How do you fill in a hole in sheet metal?

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I bought a used tailgate for my 75 Bronco. It's in very good condition with the exception of two or three small holes that were drilled into the outside panel. The holes are maybe 3/8" in diameter. How do you repair or fill in these holes? I would normally hold a small piece of copper behind the hole and just fill it in with filler metal. The problem is that I can't get behind the panel because the tailgate is enclosed.Lincoln AC/DC 225/125 Stick Linde HDA-300 MillerMatic DVI MIG Miller Dynasty 200DX Hypertherm Powermax 1000
Reply:I don't do a whole lot of body work, but if I were going to fill in some spots that I couldn't back up with copper, I would cut out some patches of sheet metal (I don't know if the holes are all grouped together or seperate) and patch the holes that way.  Grind the area that you are going to weld really well and then weld the patches in by making lots of small tacks around the edges until they are welded solid.  Then grind of the excess and you should be good to go
Reply:Bondo?Otherwise, you'll just have to take more time to do it with the welder, if you can't use the copper.  It's still doable, just keep less heat into it.  Hopefully you are using .023" wire and a shielding gas to make it as doable as possible.
Reply:"Trigger weld"  CLEAN it, a little  zzzip on the bottom, let it cool.  Another little zzzip on top of that weld.  Just a little.  Again.......  If it gets out of control, get out the grinder.  Hopefully the hole will be smaller not bigger.  CLEAN helps, low voltage and wire speed helps and if you could practice on another piece that would be better.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Thanks guys and girls for the suggestions. I forgot to mention that the holes are separate and I believe the steel is 16ga. I am using .023 and C-25 shielding gas. I don't normally do body work either, but I'm trying to learn. I would prefer not to use bondo, but I'm sure there will be times that I'll have to.Lincoln AC/DC 225/125 Stick Linde HDA-300 MillerMatic DVI MIG Miller Dynasty 200DX Hypertherm Powermax 1000
Reply:Hi all. First post, yeehaa.An easy way to fill a hole with out backing it...  use a steel rivet. Use the pin as a handle and weld it in a little at a time. You will have to grind the rivet on 2 sides to get it in the hole. It should have a kinda surfboard shape. Works pretty slick.Later -
Reply:Good idea! Welcome!Lincoln AC/DC 225/125 Stick Linde HDA-300 MillerMatic DVI MIG Miller Dynasty 200DX Hypertherm Powermax 1000
Reply:Originally Posted by Carl26...I believe the steel is 16ga. ...
Reply:Originally Posted by MAC702That seems thick for tailgate skin...Would be a piece of cake if it was, though.
Reply:When you lay the wire against the part stick the wire inside the hole and against the edge and then hit the trigger. do this over and over and you will have weld inside. Just go slow and you'll be fine...mig is gravy on hole like this!!Miller Dynasty 700Miller 350P with Aluma-pro push-pullMiller 280 Dynasty with expansion card Dynasty 200 DXMigMax 215 Enuff power and hand tools to create one of anything..... but mass produce nothing!!!
Reply:Originally Posted by FusionKingWhen you lay the wire against the part stick the wire inside the hole and against the edge and then hit the trigger. do this over and over and you will have weld inside. Just go slow and you'll be fine...mig is gravy on hole like this!!
Reply:Originally Posted by FusionKingmig is gravy on hole like this!!
Reply:Originally Posted by FusionKingI been readin' so much crap about chinese welders I'm startin' to sound like one!!