There's a substantial rotted hole on the unibody frame rib that scoots right by the gas tank. I made up a "U" shaped patch that would fit over the unibody rib and am planning on welding it (as best I can)
in place to cover over the rotted hole (see attached pix). I'm probably not going to be able to fit the welder head in all places but I think I can get some welds enough to secure it, and maybe put bondo or equivalent around the seams
that don't have welds. It's a pretty tight fit. When I do this welding I'd try and have the gas tank as empty as can be. My question ..... does this seem hazardous.... welding near the gas tank? Or maybe the welding is far enough away as not to be an issue
so long as I'm careful..... ??
Thanks.

 

If it were mine I'd pull the gas tank to get the access needed to fix it.
Structure is no place to take shortcuts.

That section repair piece looks pretty good BTW.

 

Welding that close to a gas tank is extremely dangerous. Even an "empty" tank contains highly explosive fumes. A single spark could cause a serious fire or explosion.

Do not attempt this. The proper way to do this repair is to completely remove the gas tank from the vehicle first. It's the only safe way.

 

If you're not making a true structural repair by doing it correctly {cut the rust out,fit and completely weld} then just use body filler over the hole and hide it instead of risking your life for a simple patch that has no benefit....

 

Autobody adhesive
3M 8115 is a structural adhesive that’s not cheap but will work well. The applicator is also expensive but other versions Are out there. Autobody toolmart has reasonable pricing

Ron

 

Used correctly structural adhesives are no joke.
Commercial aircraft manufacturers have been using them in production planes for over 70 years.