Place your plates together and pray

[caprinut]

The inner wings of my car have strengthening plates where the antiroll bars are located, both the plate and inner wing have blown out with rust due voids between both. I am patching the inner wing with new metal and the plate is bought but is not quite same as oem of course which does not sit on the inner wing tight even if I could patch it dead right. What could I fill the void which is inevitably created and still plug weld the pate on and not end up with the situation again.

Bert

 

[maroon]

you don't plug weld anything if making a patch repair. seam all around.

 

[steveo3002]

cavity wax ? warm it up and trickle it into the gap

 

[caprinut]

you don't plug weld anything if making a patch repair. seam all around.

I was referring to the outer plate, I suppose you might call it a cheak plate, a double plate, or a doubler in aircraft, plug welded upon a patch repair in the inner wing the oem would spot weld the inner wing and plate together creating a void when new!!!

Bert

 

[tom2207]

beat one till it touches the other ,,, plug weld , and repeat , then dress the whole lot to look stunning .
looking through the holes for the plugs will tell you what part needs knocked what way ,,, its way better to get them to be touching or as close as possible before you start to weld any of it ,,, its slow work but patience will be rewarded.

 

[mr haynes]

Using galv should help too

 

[Dcal]

For stuff like this, weld through primer or high zinc primer (galvafroid) is you friend.
It gets burnt off at the welds but some stays to provide protection.
I also like using galv sheet as @mr haynes suggested.
Certainly helps, but watch the fumes. (wear a mask)
Some people even use stainless but I'm not so sure.

Make sure the finished repair is completely air and water tight.
Without both you won't get rust.