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HOW TO PLUG WELD HOLES IN AUTO BODY PANELS
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- Опубліковано 14 сер 2024
- Here's a quick video on how to plug weld sheet metal using mig without blowing yourself a bigger hole than you started with.
My names Matt Urch and I own and run Urchfab welding and fabrication.
I specialise in custom automotive fabrication from building roll cages to complete one off builds.
I built the worlds most unique and oldest drift car known as the drift rod which can be found on my channel.
So if your into grinding, welding, fabricating, drifting, going fast etc, your in the right place!
I’m an aircraft welder.. another tip would be to get yourself a copper plate, put it in the back making sure it’s tight and weld the hole in a circle one shot.. The weld won’t stick to the copper . Added advantage is that it will pull the heat out and helps with panel warping.
Yer my mates told me that trick. Def gonna do it to my project
millermatic 135 .025 wire 7525 mix gas. I'm getting ready to lay down plug welds for a louver panel that's supposed to be bolted to a Jeep Hood. customer understand situation with weld versus bolt. I'm mostly concerned with warpage. keep a wet sponge a hand, tack and dab planned. last minute research for tips. I know about the backing trick and plan to utilize it in six areas. did not think about the ability of heat draw to prevent warpage. kudos sir kudos
I take a piece of copper pipe and hammer the end flat, then bed it to whatever angle I need to reach the backside of the hole. This gives a nice long reach into confined spaces
he explained at the beginning that he will usually do that but sometimes you can't get behind what you're welding. which makes sense to me since a lot of welds on autobody panels are closed on the backside.
@@rockharvey5787Excuse me for asking but how would you temporarily anchor the copper in place/on the reverse of the area you need to weld please?
Hey man, just want to say that I recently picked up a gas mig welder, and you single handedly have taught me more than any other UA-camr BY FAR. Every time I type in a how to on welding your videos are the only ones I watch
Great quick tip style video and nice demo also. Thanks for helping people and making videos with the real techniques welders use to handle tougher jobs. No matter what anyone wants to say this works well.
I know here in the states "plug welding" is basically drilling a hole in a piece (like a floor pan replacement) so you can rosette (simulated spot weld) it to the frame rail, or something like that. This was a helpful video, but the person who asked about plug welding may have meant something other than the topic of this video. I've been using this technique to fix hole I blew through doing some rust repair on my truck. Thanks!
Yeh They call that plug or spot welding here too, not sure if he was asking for this or not but it should help a few out either way. Cheers
That video is a blessing! My friend told me about that and then she showed me that trick!
Very useful!
May Kemppi bless you!
Thank you so much. I’m a novice welder and this was really helpful. Straight to the point. Thumbs up and subbed.
I figured this technique out last night by trial and error of blowing holes it worked really well and it keeps a lot of heat off the panel to prevent warping
I just did this today on my project car, it was my first time welding for real. Someone riveted in those ugly rubber strips on my Mk2 jetta so I had to close them up. I figured out to use this exact method after blowing out a few holes. I thought it was wrong but its nice to know it was an acceptable way to do the repair.
When i first started i remember all the fun i had chasing holes round a panel just don't generate to much heat just takes a little practice like anything but a good technique to have in your box of tricks
Very cool. I have a bunch of holes that were drilled in my M38 Willys. The techniques you demonstrated will help me get started. I'm going to start with something that's out of plain view and then proceed to the outermost panels. From Texas, thanks for the fun. :-)
Brilliant. Ive learned this already the hard way ha ha ha and its good to see a very talented fabricator do this so precisely!
Great tip, I’m currently in the process of doing a “shaved engine bay” will definitely try this technique out.
This will help me so much during the restoration of my 83 Chevy k10 pickup. Someone probably decades ago drilled 8 holes on both sides of the bed for what I assume was bed rails. Thanks so much
Exactly what I needed to learn. I have some many holes in my Nova floor
Hahaha same here. Reason I watched video. :)
You should use a piece of copper bar stock ( 1/8-1/4 x 1x 4 ) for backing. No sticking and draws heat for good plug . old school !
William Allen, yep copper is the stuff for heat sinks, but its getting tricky to find decent copper, I hammered some plumbing pipe flat for backing and it was a plastic sandwich! lol, as Matt mentioned, aluminum might be a better bet depending on copper prices and quality in your neck of the woods,I'm always on the look out for old copper as its usually better than some of todays stuff.
A Thor copper mallet does the job just fine and you've got a wooden handle to boot!
@@jonathangriffin1120 what about if you can't back the spot ie on a floor plan. I think that's what he's trying to show
@@brettwilliams657 Amen.
Glad I found this video! Technique worked with flux core. Keep up the great work!
I believe, and correct me if I'm wrong, flux core is a pretty hot method of wire use. I would lean towards 7525 mix for carbon steel. possibly run a little more cup and stick out away from material to keep it cool.
I'm getting ready to add louvers to a Jeep Hood, a little sketchy about warping no concern with filling the holes. I wanted to see if urch touched on it.
Here's a better way of filling holes... punch out circles of metal the correct size, then TiG or flame weld them in. If you must use a MiG, use .023 wire to weld in the metal circle. If the holes are on the small and fiddly side, drill them out with a step drill to a more manageable size and punch out the appropriate sized metal replacement disc.
I saw Ron Covell doing that - a window into a different world.
Great real word demo of whats possible.
This is awesome. Im working on my 73 Lincoln Mark IV and did away with the vinyl top and it's chrome trim. Been trying to fill all the holes and ended up blowing a few holes so going to try it again and get it sorted! Thanks!!
Thanks for this I'm going to be practicing on an old car door soon doing spot welds.
Thanks. I’m filling in the trim holes on my father’s big window Ford uni-body truck that’s getting a coyote swap. Super helpful
I learnt how to do this by accident trying to use a flat copper pipe as a backer which was extremely difficult and tiring trying to reach around to the other side of the fuel tank sump. I ended up just barely pulling the trigger and found that I could kind of "melt" a thin layer over the sheet metal then "blob" a weld and build off that fresh metal. You kinda end up chasing the blowout hole but eventually you overtake it and end up with a plug. It's more about having a really flat direct angle and touching the tip...let it arch and just dab the weld....don't try to actually weld it. Fractions of a second, jerk the trigger...then once you've got enough weld in there hit it with a proper shot and the weld will fill what void is left. It only works on the weld metal, not the think sheet metal.
This is handy for me because i don’t really like bright work on my older cars. I remove the trim and plug the holes for a cleaner look
I miss aligned a hole on my rear quarter for a wide body fender by a few mm if I was to weld the hole back like this would I be able to drill another hole through it or would it just break the whole weld ?
Great vid. Copper works just as good, if not better as a backing plate.
Great video!
I just did this this afternoon and figured out the same process but wound up getting a good warp and a sizeable burn through hole in one of several drilled holes I was filling on a 40s Chevy quarter panel area. The rest i did were ok but that warpage and big hole I made frustrated me. I waited away for now. Can't get behind this area so it'll need to be pulled out with pins and a knocker. I haven't welded this much in 30 years, I should've practiced a few days first.
Great video. Im about to replace a radiator support on my rx330. Can you please tell me what size wire to use on the spot welds holes? And what number to put the machine on. Im using a cheap Harbor Freight one. Thanks so much..
YOur videos are awesome.. thank you for sharing!! I'm curious about the "17 volts" for thin sheet metal. I have a good welder however it's telling me to only use higher voltage for thick metal and my machine only goes from 1 to 10.. there I must misunderstand something here. Any chance you can explain further on the MIG settings? Thanks ever so much!!
Very good very good thank you for this this helps a lot thank you again
Copper is great, I see your tip is level with your cup, my old mighty mig with CO2 was great for this but I struggle with my inverter with mixed gas
I am new to welding this tip was really helpfull. Thank you!!
Question what do I do to clean up on backside do I add just a little more then grind? Because it would be on my truck bed where it will be seen on both sides, Thank you if you could help me on that.👍
Thats kool i kinda self taught myself that from welding thin body panels
I’m trying to weld floor pans on my car and I keep burning through the sheet metal what do I need to do to not burn through? I’m using a 140 mig pro by Lincoln
Those are nice clean holes. Now assuming most people have rough rust holes is it best to drill through them to create a good clean hole? Helps to remove bits of rust too......
Super useful info for when I use my everlast mig welder
The first hole you did, how long in real time would a hole like that take?
I'm struggling to do this to my motorcycle gas tank. Initially I was just ceiling up pin holes and hair line fractures blue a bigger hole in and now I'm making it worse and worse I'm building it up the way you suggest in the liquid gasoline is still finding tiny peepholes to weep out of. Anyone have any insight?
I want to build a custom roof hatch on my van but wanted to know if I cut a 30x20 hole and push up a 2"x2"x 1/4" stainless steel angle frame from the inside if the ridge can be welded so that it's water tight and rust proof? The idea is at that clear hatch with weather striping where it makes contact would pressure down on the roof and water would have to penetrate that seal and climb up. Basically I would be using the top part of the hatch only and would secure t the welded frame..... Possible? Asking in that most hatches require a mess of caulking, drilling and backing and the space around the seal always looks like sloppy house roof work.
So, the Dolly is a big chunk of non ferrous metal that is coated in paint?
Whete are you based mate? Would you be interested in some work welding a few holes up in a steel motorcycle mudguard?
Great short video, I really appreciate your awesome!!
I noticed that the metal you are using is a lot thicker than what they have on car fenders now days. In fact my fender is so thin that it looks like tinfoil. How are you going to weld that?
Biggg help bro. I blew a hole in my exhaust welding it up. Just kept getting bigger n bigger
Great and to the point have small holes in my tj floorboards
Thanks for the lesson it helps alot
How do I make the rust not come back? Lol...getting a wheel well repaired with new metal and people keep saying the rust will come back. Esp at the weld spot in future because water will somehow get in...really bummed about this because I just got the car smh.. can I Plasti dip over the repair to ensure no water ever comes into contact with the weld repair again? Lol. Best options to make sure the wheel well doesn't rust again at the weld spot ? Thanks for any replies. Need some optimism lol. Going to be paying $800 for a wheel well repair ( cut out old metal and weld in new )
Would you be able to use a tac weld to repair a pinhole in a motorcycle petrol tank?
How about just backing the hole with a piece of brass or copper?
thanks, gold and simple!
what is the ampere and voltage for car roof... ty
Nice, thanks.
Will this technique warp the metal of an older 70s car?
Best videos on UA-cam!
thanks mate I appreciate that, the problem I have is with sheet metal distortion after the welding, of course your part sanded smooth, ha ha, but in the real world any advice on how to prevent the sheet metal from warping and also any tips or techniques on plugging holes in vertical not flat aka horizontal position, thank you
Did you get any info on plugging vertical? I have a gap in a seam on a rocker panel I have to close vertically.
Thanks for the tip. Great videos !
Thank you so much brother! Perfect tips and people say you can’t learn from UA-cam HA
Welding a Ford Mustang firewall and not tryna catch anything on fire lol
New to welding, only had it a couple weeks. I am wanting to plug some holes in my trunk on my 93 Miata where the old rack was. What would be a good ballpark for my welder's settings? Any and all help would be appreciated!
You need the right wire....use a gas wire, not flux core. Go a .6 or a .9 wire with Argon Shield gas set at around 10-12psi. The settings are all different on every welder but for sheet metal you'll be somewhere in the "1/4" region of your dial for amps and wire speed. Don't go more than a quick shot, work close to the metal, make sure it's clean bare metal and a good bare metal ground for your clamp.......and practice practice on spare stuff before hitting the piece you want to work on.
Hi, very interesting video; I have to plug a hole right now on my recent acquired vespa, they drilled
a hole right up on vin numbers... and welders here are refusing , afraid to damage neighbors numbers; Is your mig welder used on this video gasless ? Thanks for posting, oscar;
Hi, what can you say about your welding machine (gys 200-4 xl)?
I plan to buy the same
(in fact, I was looking for a video review and found your channel, then you were from a few weeks from upload video about it. Thanks for the high-quality video. Best regards from Ukraine.)
After a certain amount of time, what do you think of him?
Now would you choose something different?
Did you try to use argon arc welding mode (tig) in it?
Hi, I have only used it in mig mode and I was happy with it but it broke and had to be sent back for repair less than 6 months from new. I have it back now all fixed. I think if you have welding experience and don't need the synergic function then you can get a better more basic machine for similar money. but I will say its extremely simple to use, and works well. I,m testing out a new mig at the moment which will be in my next video www.inverterfusion.co.uk/product-p/if123500.htm Its really impressive!
good tip about the aluminium
Top tip. I tried this on a rusty lawn mower deck. It was ok on the surface, But rusty beneath the surface so kept blowing holes as iron oxide messed up the weld. Any tips for this scenario? It must happen alot on rust repairs where you appear to have good metal which is rusted on the back side. Thanks :)
try 0.6 wire and 90/10 argon co2 mix. it will make life a bit easier but if your trying to weld to rust your never gonna get decent results. cheers
I always use 6011 stick rod on rusty steel. I agree with you though if you want decent results you can't be welding over rust. I was taught if you weld over trash your welds will be trash.
Ok thanks... thought as much, but always like to ha e thoughts confirmed where poss:)
Jonathan Cooling In many cases using a flux cored wire will help with rusty metal. In my opinion about 50% of the problem with mig on rust is that getting a good circuit is almost impossible. A wire feed welder keeps feeding wire at a constant speed even when the ground breaks up or the wire makes poor contact at the puddle. If you use like NR-211 wire you weld with electrode negative. So if you get the area cleaned up good that you are going to ground to it will help. There are always 2 sides to your grounding clamp. The side that the cable leads into is the more conductive side. Always hook the more conductive side to the spot you cleaned. I know that sound obvious to the point of being stupid but I have seen many welders do it wrong.
Love the work, glad to see youre getting into the swing of youtube, where about in somerset you from fella?
Cheers, from Glastonbury originally, living in Dorset now.
Helpful video as usual, thanks. What did you use on the grinder to smooth the welds please?
Flap disk, cheers
Usually an 80 grit cleans up MIG welds pretty quick...
Nice.
what ttype of welding u usiing'
?
im gonna kidnap this guy and lock up in my garage till he welds up my car , lol!!
Thanks for the Video, can you show how to intimidate spot welds ( car body material )with the Mig, my attempts have not welded the to sheets together
will do, Cheers
To do a plug weld with two pieces, make sure one is flat and one has a hole. Both pieces MUST be clean bare metal and where you clamp your ground. Use welders vice grips to clamp the piece tight together. Set up your welder for the metal thickness and wire...sheet metal usually takes a .6 or .8 even .9 wire. A gas wire with Argon is much easier and cleaner to use. Get the wire speed right, the amps right for the thickness, get the wire close and almost vertical and pull the trigger. Work it around the edge then into the centre....you might need to try twice or three times because it'll heat up and risk blowing through before you fill the hole. Once you've filled it, use an 80 grit flap disc on an angle grinder and grind it down flat....take it easy, grind...back off...grind...reassess...grind etc.
You'll then have something similar to a spot weld.....practice on some spare pieces until you're comfy with the settings and technique.
Why not use a copper backer to hold the puddle?
Yeah I was going to say use a piece of copper but somebody beat me to it that's if you can get to it. 👍👍🇨🇦
Good tip again keep em coming 👍
Cheers
Thanks for sharing
Can you be further away next time?
hey man this was a good video thanks a lot you really helped me out. will this work on welding a hole in gas tanks?
Make sure to take the gas out of it first
Nice technique
great video.. thank you very much..
Good Tut!
How many volt or ampere
Thanks for the info
Use copper block in back myself,works perfectly
Thank you.
Good video. Were you using flux core wire or some kind of gas through the welding nozzle?
Argon co2 mix gas. Cheers
Urchfab ok great, thanks. I'll have to see if I can get the kit (if its not too expensive) for my Lincoln MIG...
Thanks brother 🙏
What wire speed are you using?
But what about the gas reaching the weld when you hold the torch that far back??
Seems to work out ok.
if it doesnt work well just use flux core
everyone who welds thinks they are masters some of the most proud people are welders, lol.
Very usefull!
Nice!
What usually happens with this blobbing it does not allow weld to go deeper that the thickness of the panel when you grind it back flush you still have a hole albeit smaller, meaning there must be parts of the hole that are thin !
Thanks super helpful
Thanks!!!
You said at the end of the video.... just 17 volts on the mig.... did you mean 17 amps? As 17 volts would not weld that surely...
17 volts is quite enough for that job, you can weld with 12volt car battery, amps count
lol @ all the dislikes. Thank you Mr Urch for sharing the technique.
Works well on new thick metal I guess. This old thin shit ain’t having it
You should use a piece of copper bar stock ( 1/8-1/4 x 1x 4 ) for backing. No sticking and draws heat for good plug . old school ! Also check this video out, Jode knows his stuff ! ua-cam.com/video/mIdYzpIWUl0/v-deo.html
yes this is for when you cant get to the back side of the hole. Cheers
Back it with Cooper much easier
Ill be impressed when someone welds a coke can thickness
Guys that’s not the right way to plug holes you weld should be all in one not spots here and there it’s not a strong weld plus a strong weld you should be able to see marks on the back of the metal
Put a piece of copper on the back .....weld away . Hole filled