Good way to fill these holes?

[6ply]

I acquired this stand for my own use outside the home workshop. It needs to be fixed up and painted to make it look a bit more respectable. I'm tempted to weld plates to the open ends, and I definitely want to fill the drill holes. I'm tempted to cut a rectangular section from the top and weld in a repair plate. Or should I plug the individual holes somehow? 3mm wall. Looking for collective ideas. Thanks

 

[RWD3M]

I think I'd probably just drop some discs of the same thickness and diameter inside those holes, both chamfered, and weld them in.

The small one will plug easily enough.

 

[123hotchef]

u could plug weld those bigger holes with the mig if your careful

 

[6ply]

No mig. Stick only.

 

[Mark 5]

I acquired this stand for my own use outside the home workshop. It needs to be fixed up and painted to make it look a bit more respectable. I'm tempted to weld plates to the open ends, and I definitely want to fill the drill holes. I'm tempted to cut a rectangular section from the top and weld in a repair plate. Or should I plug the individual holes somehow? 3mm wall. Looking for collective ideas. Thanks

I'm not a welder or own any kind of rig but looking at it,

1) your idea, cut the section out, some magnets, clamp and weld in place a new section, grind repair to a smooth finish.

2) Find some nuts that will jam in to holes, fill nut holes with stud or bolts, weld all in place, grind the heck out of repair, leave to a smooth finish.

 

[Agroshield]

You could slide in a piece of 5-6mm plate as a backer strip, jam it up into place and then no matter what you did to weld the holes shut, you would not burn through.

 

[Jelly_Sheffield]

You could slide in a piece of 5-6mm plate as a backer strip, jam it up into place and then no matter what you did to weld the holes shut, you would not burn through.

That would be my approach here too.

Even accounting for burning a whole bunch of rods to lay down weld on the backer that fills up the holes... It would still be way quicker and less effort than cutting out and positioning small coins of 3mm to patch the holes.

Also less effort than putting a whole panel in, as you're just running beads on plate.

 

[Pigeon_Droppings2]

That would be my approach here too.

Yup +1 for this approach....clamp in a backer plate and off you go.

Cutting in a new piece is more work and more risk of problems.

 

[Agroshield]

This is more an academic than practical question:

If the backer plate were aluminium or copper, would that prevent the weld sticking and allow it to be removed afterwards?

 

[6ply]

Yup +1 for this approach....clamp in a backer plate and off you go.

Cutting in a new piece is more work and more risk of problems.

I kind of agree with you regarding more work (more cutting, certainly) but I reckon I can weld neater straight runs than fill in holes. Maybe I just need to practice. I might surprise myself.

 

[Pigeon_Droppings2]

Think cutting would also work...only issue I guess might be how much heat will go into it.

 

[Jelly_Sheffield]

This is more an academic than practical question:

If the backer plate were aluminium or copper, would that prevent the weld sticking and allow it to be removed afterwards?

Generally yes, but the backing bar must be thick enough to stay cool, and not get melted by the arc or sag down whilst the weld metal is still cooling.

Basically the same as a backing bar for a root pass... Ceramic is an option too.

 

[pedrobedro]

I'd get a piece of 3mm plate and put it on top, sod all the messing and cutting

 

[RWD3M]

No mig. Stick only.

Ah!

If you're up this way, I'd happily either let you use my mig or do it for you.

 

[Pond frog]

Do you know what you’re going to use it for? I’d probably use it as a saw horse so I would fix a sacrificial wooden batton on top and the holes would be irrelevant

 

[6ply]

Do you know what you’re going to use it for? I’d probably use it as a saw horse so I would fix a sacrificial wooden batton on top and the holes would be irrelevant

Mostly clamping whatever to, for the purpose of grinding, cutting or welding. It's heavier than it looks, making it quite stable.

 

[123hotchef]

leave the holes and use them for some nice clamps save messing about altogether

 

[brightspark]

leave the holes and use them for some nice clamps save messing about altogether

handy for drilling holes in plate clamped over them

 

[Erie Fred]

I kind of agree with you regarding more work (more cutting, certainly) but I reckon I can weld neater straight runs than fill in holes. Maybe I just need to practice. I might surprise myself.

cutting into box tubing will release stress's.
Might banana on you

 

[Dilkris]

I'd get a piece of 3mm plate and put it on top, sod all the messing and cutting

Agreed
Or.... cut it off - turn it upside down and weld it back on.....