Frame repair with washers
 

Looking back in the past I really did some crazy things to the chevelle when it was being drag raced. At that point in time the biggest concern was make it go faster and faster and do whatever it takes to do it. One thing I did was drill out the front frame of the car with a 1.25" holesaw. Well it came time to fix all this crap since I have the engine and fenders off the car.

here's some of my swiss cheese. lol
http://www.allenitllc.com/hotrods/ch...pair%20004.jpg

I picked up some washers that fit the holes in the frame exactly and then proceeded to weld all the holes up.
http://www.allenitllc.com/hotrods/ch...pair%20005.jpg

I then ground down my welds.
http://www.allenitllc.com/hotrods/ch...nd/frame-1.jpg

And rattle canned it all with some flat black rustoleum. It looks so much nicer now! turned out really nice! Especially for a $3.50 repair. Bowtie smiley

http://www.allenitllc.com/hotrods/ch...pair%20001.jpg

http://www.allenitllc.com/hotrods/ch...pair%20003.jpg

Looks great! Can barely tell they were ever there after you blended it in and painted

Yes it does look nice but I doubt if that approach would return the chassis to factory strength values. Was that your goal?

nah, there's really no need to strengthen that section since it doesn't do much in front of the control arms, but hold up the core support and fenders. The washers are the same gauge as the frame, but it's probably not as strong if it were to be in a collision or something. I just wanted the ugly holes gone since it's now a street car. I've been wanting them gone since I made the mistake of doing it 12 years ago. LOL