filling sheet metal bolt holes

[hotrod1]

The front panel of my bed (56) sits higher than the side panel (why did they do that) by 1/4". I have to fill the bolt holes and drill new ones 1/4" down to make the bed sides and front level.

How do u guys fill those? Just weld and grind, or make plugs and tack them in? If u make them, how? I think that they are 3/8 or 7/16?

[OKGMC4]

I got lucky and my father in law made a bag of various size plugs for me. He's a machinist, so I guess any machine shop or metal working shop could do the same for you. You other option is to use a brass welders spoon and top fill them. I've done both and it's about the same amount of grinder work either way.

[papastrk]

Make plugs using tin snips and scraps of sheet metal. Tig welding is the best for this type of repair. Most of the plug will be drilled out when the new hole is relocated, so there won't be much weld remaining.

[72Mountaineer]

Use a coat hanger. Wedge it in there crossways or even straight, just something to weld to and make up some space, works great.

[1project2many]

Another option is to use a huge block of steel as a backing and mig weld the hole closed at low heat. The weld won't penetrate the large block and the block can easily be removed.

[Speedbumpauto]

Aluminum strap is the poor boys brass welding spoon. You can clamp or hold a peice of strap on the bottom of the hole and weld it from the top. Anything 1/2" or less, that's what I do. Sometimes the thin fender washers make great plugs for larger holes and they have a ready made hole to hold them while you tack. Just touch the edges on a grinder to get the galvanize off them.

[Kabwe]

Man get some nails the size of the holes weld them in and cut off the stem and grind flush. That way you can use the stem to hold while tacking them in.

[_Ogre]

I have a big brass punch I hold on the back side while I mig the front
I've heard that a piece of flattened copper pipe works well too.
Whatever you use keep a bucket of water handy to cool it.
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[hotrod1]

Great Ideas!!! Thank you everyone!

[Kabwe]

You have a tig welder use it. Tig is wonderful for body work.

[55metalmonkey]

My 2 cents
1: Nails work like a charm
2: copper "puck"
3: brass spoon/ punch
4: plug weld the hard way using short built up tacks

for larger holes 1/2" and up I found that the flat style steel frost plugs work great after you hammer them flat

[codger30]

Yeah nails, great. I bought a project years ago where the guy used nails, trouble was, when you looked inside the panel, all you could see were s##t loads of rusty old nails poking through.
He even frenched the rear number plate half an inch off centre which was real noticable with the boot handle right above it.
Bryan

[DransportGarage]

I'd love some pics of the nail trick...

[solidaxel]

This worked for me and it was very fast.

I went to the hardware store and found a bulk bin full of nails with a 1" piece of sheet metal attached to it.

The guy said they were for nailing down roofing for a stucco or roof paper.

You do need a second hand to hold the nail on the outside of the firewall while you spot the 1" square on the inside.

When they are all tacked go to the outside and finish the mig weld as you already have the backing in place.

Grind off the nail and dress up the weld and a little filler and you are complete, fast cheap and easy !!!

I have been known for using nails of different sizes depending on the size of hole, there are some VERY large spikes in the hardware store which will match 5/16 holes !!!!!

[Newtz67]

All very good ideas.

[mr48chev]

I bought one of these off Ebay a while back and It's a nice piece.

One of these= http://www.ebay.com/itm/Welders-Help...item53ec594786

Eastwood has some copper backing panels but the price is a bit stiff for what is there.

I don't know how I am going to hold it an weld in some spots but it is heavy copper and is a decent unit for the price.

If you know someone in a sheetmetal or fab shop you might be able to get them to save you the punch plugs from the punch press to use to fill holes.

[Kabwe]

Originally Posted by DransportGarage

I'd love some pics of the nail trick...

Not really any trick to it.

Lets say I wanted to fill this hole.


Get a nail with a head the fits nicely in the hole. If the hole is smaller you can use a step drill to open it up a little. Don't use a rusty nail as I did. I did this on a trashed fender for demo purposes.

Tack the nail in place. You can use the stem to hold it in place.

Cut the stem off.

Finish welding it in and grind flush and it should look like this


I use this method to fill all trim holes.

[mr48chev]

Thanks Kabwe, that's probably one of the most useful things that anyone has posted and will get used about 50 times on my 71 GMC. My uncle drilled new holes every time he hung something on that truck.

[Kabwe]

Originally Posted by mr48chev

Thanks Kabwe, that's probably one of the most useful things that anyone has posted and will get used about 50 times on my 71 GMC. My uncle drilled new holes every time he hung something on that truck.

I'm glad you found it useful. I like this method especially when you don't have access to the back. Using the stem as a handle comes in really handy.

[hotrod1]

This is great. Little tricks like that can save a huge amount of time and anguish.

[DransportGarage]

Thanks, Kabwe & solidaxel. I had been using washers on the large holes and just mig-filling the small holes. This will cut down on both the welding and the grinding.

[Kabwe]

Originally Posted by DransportGarage

Thanks, Kabwe & solidaxel. I had been using washers on the large holes and just mig-filling the small holes. This will cut down on both the welding and the grinding.

That's why we are here buddy to share and learn.

[solidaxel]

Originally Posted by kabwe

that's why we are here buddy to share and learn.

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