Originally Posted by joecaption
And how do you want it to look. What it to look right then replace the door.
lol no. use bondo.
it has excellent thermal properties which is why it is used on cars exposed to the same harsh environment. I have never NOT been able to make a metal door look like new with bondo.
and yes, filling the inside of the hole with foam is good, and will provide a backing for the bondo.....fill the whole thing then trim the foam back and leave just a little (1/8-1/4 inch).
we are talking about the little quarter sized hole for the bottom handle right?
If bigger (like the door knob hole) then fill with a circular wood block the same size, gorilla glue in place, then bondo over that.
remember the bondo dries very hard so within the first hour make sure you scrap down the excess while it is still workable....you want only minimal sanding to feather out and blend. If done correctly it should be quick, easy, and look perfect.