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- Thread starter Lil'John
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i've been able to with low heat start the edge of the hole and fill it in...but it takes a lot of work and swearing
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Weld the holes
Puddle weld with small diameter wire at just enough heat to fuze or join metal or you will just "blow through". Take your time and let the metal cool down to help prevent this. Depending on your welding skills, you may be able to do this without a backer, brass plate. Don't use a similar metal as it will bond, this is okay if you weld a silmilar metal backer first. If this is the route you go just make sure you get a full perimeter weld or moisture etc.. can haunt you later.
I would weld before trying a caulk or plastic patch as over time they may become brittle and then moisture will come into play again.
Hope this helps.
Puddle weld with small diameter wire at just enough heat to fuze or join metal or you will just "blow through". Take your time and let the metal cool down to help prevent this. Depending on your welding skills, you may be able to do this without a backer, brass plate. Don't use a similar metal as it will bond, this is okay if you weld a silmilar metal backer first. If this is the route you go just make sure you get a full perimeter weld or moisture etc.. can haunt you later.
I would weld before trying a caulk or plastic patch as over time they may become brittle and then moisture will come into play again.
Hope this helps.
LC_Hamma
The Anti-Leafer
I'd cut some smaller O.D. circular filler pieces w/ 16 ga. Center up the pieces in the hole w/ a magnet underneath. Strike on that piece & pull the puddle outward. Remove magnet after 2 or 3 good weld connections. Magnets aren't very good conductors in my experience, just good enough to hold your piece as you begin tacking.
Funny. I have project planned next summer to DRILL some drain holes in my floor pans.
To fill holes I cut slices from a 3/8" steel rod matching the thickness to the material being patched. Then I drill the hole using a step drill to make it nice and round with a snug fit. Usually the plug can be carefully tapped into place for welding. The drilling cleans up the edges of the hole for easier welding.
Holes 1/8" or smaller I plug weld. Sometimes backing it using a thick piece of aluminum that has been sprayed with spatter release. Sometimes a helper can be useful in holding the aluminum , with a gloved hand. Holes 3/4" and larger I cut the plugs on a drill press with a hole saw without the centering drill bit.
I just completed an FJ40 rescue with my son and we welded a total of 500 holes. What were the POs thinking?
Holes 1/8" or smaller I plug weld. Sometimes backing it using a thick piece of aluminum that has been sprayed with spatter release. Sometimes a helper can be useful in holding the aluminum , with a gloved hand. Holes 3/4" and larger I cut the plugs on a drill press with a hole saw without the centering drill bit.
I just completed an FJ40 rescue with my son and we welded a total of 500 holes. What were the POs thinking?
LilJohn, if you have enough Welding experience you can do it without backing plate. Start at edge of hole and give a quick hit of the trigger until you have a tack and continue around the hole. Or use a backing plate made of copper and it will be easier to fill. No need to use plugs, holes are too small. Let us know how you made out and what method.
Thanks Bob.
Thanks Bob.
LC_Hamma
The Anti-Leafer
You would do this for even these relatively small holes? I'm not sure I see an easy method to create a 3/8" filler
Well, depending on your skillz, condition of metal to be joined, patience & heat setting, you could just strike & pull inward to fill with weld. I've done it plenty of times with good success. More cleanup is usually involved though. Don't warp the area w/ too much weld mat'l. at one time.