i developed a rust spot from my rear passenger door jam into the wheel well...the hole is about 2x3 in the door jam, and about a 1x1'' in the wheel well.
i cleaned it all out which is why the hole is bigger, should i just bondo the hell outta it? or is there a better option

pictures can be provided if needed,

thanks in advance

 

Expanding foam, and bondo. I have the same issue you do, I might take a sawzall to pic a part with me one day and have at it.

 

Yep foam, not the best fix because it holds water but the easiest and fastest. Heck gm put foam in there anyway to quiet sound. Thats why there`s rust!

 

Is expanding foam something I can purchase at Walmart? Lol. Yea the foam already in there is soaked. ..shocker...since its hollow inside, should I get the wet foam outta there and buy the bondo self adhesive mesh and go about it like that?

 

Depends how pro you want to be. Expanding foam (yes walmart) spray it in, let expand and cure, trim flush, sand around the edge to expose metal, bondo or fiberglass sand down and paint

 

Gonna head out and grab all the remaining supplies including expanding foam. Thank you for the great advice guys. Will hopefully have some before and after pics sooner than later....cant keep up with this damn weather lol

 

so this is what im dealing with, gonna tear some more out and take out the wet foam before i start re-foaming

 

If you REALLY want to go the foam route instead of welding in some new metal.
Search around on the internet, I believe there is some expanding foam that resists water if I have read correctly. Do some searching first.

 

say i dont use foam at all, i did buy it but can return it. would it hurt anything? i know its basically used for soundproofing.

 

You would need access to a welder or someone who welds to fix it properly. Depends how llong you plan to keep or how long you think the truck will last you. Foam and bondo 2-3 years, cut out ALL the rust and weld 10+