Welding Up Small Holes In Sheet Metal

Try going for a wire of 023 inches when welding sheet metal.

Welding up small holes in sheet metal.

In this video im showing you the process i use to do small rust repairs where a complete panel. Make sure you always work with a small wire diameter to avoid making holes in your sheet metal. Regardless of the reason you will have holes that need welded shut. It will inflict less damage on the metal as well.

Here s a few tips on repairing rust holes in car body panels. Imagine a butt weld on 20 to 24 gauge metal. Welding thin metal demands tight fit up. Make sure to use an electrode wire that is thinner as it uses lesser heat and prevents blowing holes on to the sheet metal.

Never go for a thinner base metal for the auto body sheet welding to get the best result out of it. The easiest holes to fill are small holes about the diameter of a pen or smaller. 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. Fit up and joint design.

Small wire diameter will let you have flexibility if you mess up anything. For these types of holes i start by cleaning the area around the hole with an angle grinder and flap disc. This may be due to burning through the thin sheet metal welding molding holes fabrication or other reasons needed. 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.