Filling Holes

[PSim]

I'm new to welding after finding a small hole in the outer sill of my project car and thinking 'i'll have a go myself'. I've been told by a few people that plating it is unnecessary and to just 'fill it with weld' but I haven't found much information on the technique. I've only recently got my welder and am still in need of practice but would like to know how do the best job?

Oh and the offending hole will be covered by a side-skirt!

 

[fingers99]

I'd say do it properly. If the hole is caused by rot, there will be rot inside, and a lot more rot than you can see. You can't really bodge this by using a welder as a gap filler.

Sills are structural (whether covered or not) and, if you intend keeping the car, should be replaced by new sills.

 

[smillsey]

yep as fingers says.... make sure there is no rot on the inside of the panel... it there isnt then happy days, but you will be welding upside down and fighting a horrible thing called gravity, and the weld pool will want to fall on your face and set fire to your brain....

 

[pedrobedro]

Hit it with the hammer and see how much bigger the hole gets then find the good metal, grind the paint off and work back to that.

 

[fingers99]

Hit it with the hammer and see how much bigger the hole gets then find the good metal, grind the paint off and work back to that.

At least that way you'll have an inspection hole so you can survey for further damage........

 

[Tino]

When ever I have had to weld a small hole in a car, it has always turned into an “oh my god, I can fit my fist in there” as soon as I've started taping with a hammer to find metal thick enough to weld to. Don't be surprised if it's a lot worse than it looks.

 

[PSim]

Thanks for the comments guys, yeah I gather that it'll be made harder by having to do it upside-down! As for the holed spot, after giving it a good clean up and a few taps it seems like it is very localised to just the one spot (and is directly next to a jacking point so maybe some previous damage has been made there). So I think i'll carefully cut around the offending area to completely remove any rot and replace with a small plate and reseal thoroughly...

 

[Iain Westland]

dont make the plate too small, and weld opposites, inch left inch right inch top inch bottom inch left etc if its overhead, dont be tempted to keep going as everything seems fine - it goes from perfect to hot mettle on the head in about less time than it takes to say told ya.