Filling holes...

[Deyomatic]

Really simple question. People say to use a heat sink behind a body hole to fill it with a welder, but I don't remember if it was copper or brass. Which one is it?

[hammeredabone]

Copper

[Deyomatic]

Where do I get a chunk of it? I'd melt down some pennies, but they aren't copper anymore, are they?

[TV]

It is copper, and you can get it from a welding supply or try Granger.--TV http://www.jalopyjournal.com/ubbthreads/images/graemlins/cool.gifPS Make sure you don't try to fill to big of a hole,anything bigger than 1/2 inch make a filler pc.

[spudshaft]

I've got a copper "spoon" from Eastwood. Works good

[Kevin Lee]

Mine was quick and dirty - picked up a short length of copper tubing when I was at the hardware store and smashed the end flat and folded it over a few times with a hand sledge.

[Tinbender]

Brass, bronze,aluminum, or copper.

[burger]

It's timely that ask this now, as I'm hoping to do this exact task on Saturday. What do you use to grind down the welds once the hole has been filled?



Ed

[porknbeaner]

I've used copper, aluminum, and /or brass. I like copper best but any of the above will work.

Grimlocs trick with the tubing works and is a cheap way to go.

You can even use that trick when your welding and have too much gap to keep from burning it up.

Get a flap disc for your angle grinder to grind it off. Don't lean on it too much so as not to get it too hot.

Have fun http://www.jalopyjournal.com/ubbthreads/images/graemlins/wink.gif

if it don't make ya dirty it aint yours http://www.jalopyjournal.com/ubbthreads/images/graemlins/grin.gif

[Unkl Ian]

McMaster Carr is another source for copper.Or try your local scrap metal dealer,I got a piece 1/4" x 2" x 3 feet long a couple years ago for alot less than one of those things from Eastwood.

[choprods]

for 1/4" size holes pull a framing nail[16 penny nail-BARE STEEL] thru hole FROM INSIDE tack it then cut it off on outside then finish spot welding the hole ......WORKS!

[Gr8ballsofir]

Deyo, Capitol Metals on 48th street!!

Mark

[fordiac]

if youre doing the copper backing-hole filling deal, turn your MIG wire speed up so you fill the hole faster. still using a lower setting

try it. I liked it.

[silent rick]

i've used copper before. my neighbor also has some brushes out of large industrial electric motors, great for backing also. the weld doesn't stick to the carbon.

another buddy turned me on to this trick for filling 1/4 inch holes. i take large diameter steel wire, hold it in the hole diagonally, buzz it quick with the mig. the wire glows red making it easy to snap off. just grind off what's left. made real quick work of filling all the holes left behind when i removed the chrome. try it, it goes really fast.

[Tman]

Doesnt ANYONE cut sheet metal plugs??????? Hold in plce with masking tape on the back....zap...zap..zap.grind lightly then done.

[Tim]

tman,

im preety sure a filler patch is the way to go on alot of places but im thinkin there talking some preety smallholes and by the time you take and make an itty bitty teeny filler patch you could have had it done

ya know?

tim

[Tman]

Tiny holes like rust pinholes? If so there will be pitting all around the hole and it will just blow out, even with a backer. Take a unibit and enlarge to a common sheet metal plug size.....then fill.

[fordiac]

tiny holes like the holes that would be occupied by the bolts that hold the trim onto the car...

im talkin like 3/8ths of an inch or smaller...

[Deyomatic]

I think we're talking about trim holes, at least that was my original intent. I just got a bunch of nails and some practice stock, so I'm going to start practicing tonight or tomorrow, before I burn any holes in the car.

[Tman]

3/8ths is NOT a small hole!!! Nails might fill the hole, but thats where I disagree with Kenny. The nail head is usually thicker than the surrounding metal and will cause problems later when paint is covering it. Different thicknesses of metal expand/contract at different rates. You can see this on many cars as the temp changes. Same deal with panel flanging.

[John_Kelly]

I would make a perfect fit plug of the same sheet metal thickness and gas-fusion-weld it in. If you have a hole punch you can make a bunch of little circle blanks with it. I do this with trim holes all the time. Take the blank which is slightly smaller than the hole, put it on a dolly and hit it with a hammer to stretch it a little bigger, insert in hole hammer and dolly to stretch the blank to fit the hole. You then have a press fit. Set your torch to weld with just a brief touch to the seam. If you have it right it will fuse a small portion. Do this in several places, hammer and dolly, then weld it up, hammer and dolly, shrink as necessary. Makes for a perfect repair. Be sure to check the backside for good penetration. Practice fusion welding ( melting the metal together without filler rod)on some scrap first. You will be amazed at how easy it is. You can control the heat by dipping the torch in and out.

John www.ghiaspecialties.com (http://www.ghiaspecialties.com)