I did not want to start a new thread, so I'll just add to this old one.
The rust holes on my truck became to large they were adversely affecting the aerodynamics.
Holes so large you could pass a new born baby though them, and the rear wheel flares were completely gone.
Here is a thread in another forum with more photos:
Rusty old pickup truck - Razzle Dazzle Camouflage
Rusty old pickup truck - Razzle Dazzle Camouflage - Pelican Parts Technical BBS
Before:
After:
Photobucket Gallery:
S10 4x4 Pick Up by George Kachadoorian | Photobucket
Expandable foam (Great Stuff), 2-part epoxy, Micro-balloons, masking tape and spray cans...............and lots of time.
The actual tapping and spraying took a single day, most work was either before or after.
I had some fun with the details.
I also silicone caulked up some cracks and joints near the chin spoiler, it's amazing how these little details add up in the handling and performance department.
Cheers, George/kach22i