welding holes closed: largest size practical

Great idea on the file handle!

-Brad

 

I've always been curious when I hear guys say they use pennies as plugs to weld holes...
How? Copper doesn't weld. That's why we use the copper backers.

I've never tried welding a nickle, dime or quarter... but it seems like for a couple bucks that might provide you with the needed plugs.
Not sure what the make-up of them is though.

-Brad

 

I use either my copper paddle that I bought from HF or I use the 18ga. plug weld kit I got from Eastwood . I don't like to buy from them but this kit is worth the money . Sometimes you can't get behind the holes you want to weld up so I use the plugs and a magnet to get the plug tacked up . Then I remove the magnet and finish welding the plug in . Then I use a flap wheel and clean it up .
Another good place to get plugs is from an electrician or a construction site after the electricians do their thing .

Retro Jim

 

Cut big holes sq. (die grinder) , its easy to make a patch !

 

I've always used brass for backing but I work in a scrspyard so we have lots of brass to choose from. A 2" diameter brass pin about 4 inches long will absorb a lot of heat and prevent warping. We use 1/2" thick flat brass when we need to build up corners on grapples and shears when we use 325 amps with 1/16" wire.

 

maybe... maybe... but cutting out 96 or so patches ain't on the work order!
i'll definitely be thinking this over for a while longer. anybody want a half-set of '61 Falcon Deluxe bodyside moldings? just joking..... not ready to part with them YET.

 

I bought one of these things from Amazon (cheaper than Eastwood) and welded up some 1/2" holes in my floorboard


http://www.amazon.com/gp/product/B000VHZHBO/ref=oh_details_o01_s00_i00

Was doing it with a piece of copper pipe and magnet but this thing sets up a lot faster and saves a lot of time. It was a hassle getting the magnet on the pipe to where it held the pipe and stuck to the floorboard.

 

That punch looks like it might be a tool to have, but I wondered if you need the grip of Superman to punch 5/16-3/8" holes through 19 gauge with it?

never mind now that I looked at it closer I see it only goes up to 9/32 anyway.

 

I would spend the money on a Roper Whitney punch. I worked for a guy who had the cheapy model. it was 1/2 the price but twice the work.