Any tips or tricks? I have used the welding s**** for the little holes, and the medium holes i filled with steel rod or bolts and then tacked it and then sanded it down. I was told to make sure there's no little tiny pinholes left. The bigger holes I just cut some sheet metal and tried tacking it on from the inside. I'm not sure If i like my work. I have the lincoln 180HD turned down all the way, but every now and then I blow through the weld. Any advice for a first timer ? besides practice?
You can place a piece of copper sheetmetal on one side of the hole and then mig, starting at the top with very short clicks of the trigger. Then grind flat with a hard grinding wheel, finishing with a sanding disk. The metal will pool and drip down slightly making for a thinner weld. Take care not to arc on the copper. If you are going to upholster the inside with sound deadner and carpet, just weld a disk of metal on the inside. Weld from the finish side.
If you've got a precision sheet metal shop in your area, you could ask them for the drops (holes) from electronics ch***is and such. I have a bag of these that work nicely for various size holes.
I've used washers,cut plugs with tin snips,,,big areas I make a template with cardboard and trace to sheet metal and cut to fit. HRP
Bob Drake has a package of punch outs that are reasonably priced. The sizes are about 3/4" dia down to 5/16" dia. They are a little heavier than 18 ga. Very handy.
There is a jewlers punch set that will punch holes (discs) from up to 14 gauge sheet. Use them to plug your holes. As suggested earlier, weld from the inside! Check eBay for punches.
Tightly fit plugs. VERY clean metal. ESAB EZ-Grind 0.023. Copper s**** behind holes too small for practical plugs. Patient, slow welding, with plenty of cooling time in-between tacks, moving around, a lot. Zero filler.
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