Welding Up Small Holes In Sheet Metal

This may be due to burning through the thin sheet metal welding molding holes fabrication or other reasons needed.

Welding up small holes in sheet metal.

Fit up and joint design. Make sure to use an electrode wire that is thinner as it uses lesser heat and prevents blowing holes on to the sheet metal. Regardless of the reason you will have holes that need welded shut. Imagine a butt weld on 20 to 24 gauge metal.

For these types of holes i start by cleaning the area around the hole with an angle grinder and flap disc. Never go for a thinner base metal for the auto body sheet welding to get the best result out of it. Try going for a wire of 023 inches when welding sheet metal. In this video im showing you the process i use to do small rust repairs where a complete panel.

The key tip is to make sure you take the time to setup your welder for nice flat spot welds and leave time for the metal to cool between each weld. Small wire diameter will let you have flexibility if you mess up anything. The easiest holes to fill are small holes about the diameter of a pen or smaller. It will inflict less damage on the metal as well.

Here s a few tips on repairing rust holes in car body panels. Make sure you always work with a small wire diameter to avoid making holes in your sheet metal. If you are going to weld on thin sheet metal such as car body parts then you re going to have holes to weld from time to time. If the parts fail to touch each other for even 1 16 inch you have created a hole that invites burn through and a gap that can t absorb the heat.