how big a hole before you make a plug?

[Dago Red]

Hey guys, when doing body work, closing up holes, be they old bolt or whatever, what is the rule of thumb, or common sens, on how big you just weld up and how big you make a piece and weld in for? i.e. dime size you just weld, nickel and bigger make a plug?

I saw the trick with the copper behind the hole to weld against, was going to try that one some of the smaller ones.

Thanks.

Red

[shawnlee28]

Theres no set size,...its just what makes it simpler to do.
Try to weld anything too big and it will be hard and take lots of time.It is just quicker and less to grind off if the plug is used.
I would say anything over about a dime or nickle sized hole is going to be hard using a wire feed to do, unless you have a big stick welder.

[buflowd]

I use plugs that I get from the local sheetmetal shop. Usually I get sizes from maybe 1/4" to 1/2". When the metal shop punches holes for whatever they are doing these just end up on the floor. Whats neat about the plugs is they are exact in size, say 3/8", and they are peaked a little bit in the middle from the die they use. If I have a hole to fill a little smaller than 3/8", I'll use a uni-bit to make the hole 3/8" then use a rat tail file to make the hole just a bit larger so the plug will just snap in. Then because of the small peak in the middle of the plug, I'll use a hammer and dolly and flatten it out and it holds in the hole real tight. Then just weld. Hope this helps..... Bob

[Dago Red]

Thanks Bob, that is a good idea. I'll check some local shops and see if I can't get something from one of them.

shawnlee, I have a SMALL stick welder (1/8" rod max), but it is in storage since I only have it for things like welding steel to cast and other dirty stuff that the wire won't do, or getting to a tight spot.

Red

[shawnlee28]

Wire feed and the plugs will make it alot quicker and look better ,with less grinding too.