What would be the best way to fill this hole I got sheet metal

 

Do you mean plain sheet metal? Cause I wouldn't do that without an actual large cut out section from another XJ.

 

Ok. Ya I thought of that to. Just going to the salvage yard and get a cutout and punch rivets into it. That's the worst part besides the rockers. I think I may be able to touch up the other side with some fiberglass resin. I like that stuff better than bondo

 

Well, if you ever plan on trimming your fenders, now is the time to do it. No point in welding up a bunch of sheet metal and complex contours if you plan on trimming. Beyond that, I agree with WW, you'll make your life much easier if you can harvest a donor panel from somewhere rather than fabbing from raw sheet.

 

Well, since you asked for the "best" way.

Cut out the corroded section and replace it with a section that is not.

Pop rivets could be used, I suppose, but it really should be welded in place for a proper repair and to minimize filler.

 

I like your idea. Get my donor panel cut them both exact replace and spot weld and grind them welds off and fill the seam and throw red paint on. Sounds like a plan. I got access to a small welder that'll do the job

 

I did a lot of bodywork back-in-the-day. Try to cut your existing piece out an inch or two past the rust in all directions. Use it as a template on your donor panel. Try for an exact fit with no overlapping edges....you'll cuss and fight it less.

 

Ok. Ya any tips would be greatly appreciated. I need to Lear. This trait. I got my rockers both sides the very bottom of tear quarter is getting soft both sides an the two rear finders to do. The driver side rear fender is the worst of it all. I want to learn this stuff I plan on keeping my xj for a while

 

This is a good tip. Exact as possible matching is a good way to go.

 

I'd start with a grinder and a nice flapper disc take all paint and rust off and see what it looks like after you might just need a lil bondo and a good paint job after that but you can't check out the damage untill you clearly can see what kinda damage but if there's holes, yea I'd try to cut a section out another jeep cut the same section out of yours than tack it all the way around grind bondo and paint and I'd paint like the hole section rear quarter panel like such

 

This is always an option

 

Ya that way it's not different shades. Black on red wouldn't look bad

 

I'm gonna leave it all stock. Don't wanna chop it to bad. I'm not lifted ether so that would look funny.