Thread: how big a hole before you make a plug?

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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.

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