I started my yearly pre-winter rust fixing bonanza yesterday, and the worst I've got is a hole about the size of a fist. It's in the door frame of the driver's door facing outside, almost directly left of my left knee as I'm seated. It's strange how I've gotten used to this. Before, a big hole would have scared the hell out of me. But anyway, does anyone know what gauge metal to use? I was thinking about using galvanized, since I won't be able to seal the back of it. That poses a hazard with welding, if I remember correctly. Is it safe to do with lots of ventilation?