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All that sounds like too much work. Since the holes are really big, tape the outside with masking tape and from the inside blow in a batch of spray-foam insulation (low expanding). Let it set up then remove the tape and sand it smooth. Fill with bondo as necessary, sand prime and paint. Hell I've even repaired frames this way !!!

And by the way ... filling your framerails with sprayfoam will keep water and crap out and that means no more rusting from the inside out !! Doesn't weigh squat either !!!



heck why buy foam..use Newspaper......LOL