Filling small holes without welding

[dragstews]

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Welding is most likely the best way to go about it ..

 

[Bennyt]

I would only weld, everything else is a compromise and cross your fingers it is going to last.

I use these plugs from Speedway and others for holes larger than 1/4". Unibit to size and a magnet to hold. Saves a lot of time. Available in various diameters and gauges.

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[bucket]

If the holes are actually only 1/8 or 3/16-ish in size, it's pretty easy to weld those up.

It was mentioned earlier, the possibility of using fiberglass body filler, along with dimpling the steel down. Imho, it's the next best thing to welding. Simply grind the metal a bit, ding it down, feather the surrounding steel with 80 Grit on a DA, then apply the Duraglass. Sand the Duraglass down a little "too far" and skim coat with a polyester glaze.

It may be considered a little bit "hack" this day and age, but it does work very well.