Technical Sheetmetal Plugs

I'm at the point in my project that I need to weld up a bunch of holes that will no longer be needed. What is the best way to make plugs for the holes? I can weld most of them up with brass backer but was looking for a better way. I can't seem to find anything that will punch a sheet metal blank for smaller size holes (trim etc.).
Thanks!

 

Whitney punch plugs.

 

Also Blair mini-holesaws............only use a center punch for piloting and make a nice plug for your purposes.

Ray

 

… depending on the thickness needed I use washers then plug weld center; check with Hardware suppliers = ‘Fender Washers’ come in larger diameters. Get washers that fill the hole then butt weld; no overlap welds allowed.

 

I use nails , they have a handle to hold in place then grind off when done

 

i go to a local steel yard with a piece of scrap sheet metal and they punch any size i want with their iron worker [stationary equipment]. usually for free.
tom

 

And use copper not brass for a backer. The zinc boils out of brass and contaminates the weld.

 

I think Eastwood sells a kit with multiple sized round sheet metal plugs.

 

I make plugs from bolts, unthreaded part, cut a slice out, whatever thickness you need, 1/4, 3/8, 1/2, etc.

Use a unibit to make the hole exact, the plug will fit perfectly.

Rich

 

Iron worker suggestion is spot on. Find a local sheet metal/fab shop with one, bring a hunk of sheet metal, say please/ thank you, and bring some donuts for the crew. Probably end up with all the punch slugs you want in miscellaneous sizes!

 

Or, just go to the sheet metal shop and find their scrap bin....BTDT
It is so much faster though to use a copper ingot and weld them.

 

I think it is Bob Drake that sells a kit of hole plugs.

 

there used to be a shop that made metal wall studs , I used to go to and get them by the pound ( how they got paid for the scrap ) it was all pre galved so no poison worries. but they been gone since the crash in 08

 

Yeah, "Backorder Bob" Drake sell packages of sheet metal plugs. If you have a sheet metal shop in your area that has a Rotax punch they might punch out several for you in waste sheet metal. The kit that Drake sells is PN, HR-1580 , 200 pieces total of 25 pieces each from 5/16" up to 1 and 1/4".

 

You can get "unholes" from Welder Series;
http://www.welderseries.com/blog/#!/Unholes/p/50202282/category=13052955

 

WOW! You guys know your stuff!! Thanks for the help!

 

I got a scoop of a few different sizes from a local stamping sheetmetal shop scrap tub. $10 for basically a bucket full that will last me as long as I'm around.

 

Yep. Whitney #5 Junior punch available from most any HVAC/sheetmetal supply house for around $75. Comes with 7 punches and dies from 3/32 thru 9/32. Chinese and Taiwanese knockoffs of the Whitney punch kit are available for about half the money. Some are okay and others not so much but none of them compare to the real thing IMO. Once you have a Whitney punch you'll wonder how you ever got along without it in the past.

 

That's what I do, the head is the plug and the shank is the handle, the shank also acts as a heat sink and helps control warping.

 

I just scribe s circle and cut it out with Aviation snips. quick, free, accurate

 

me too and sometimes i leave a little "handle", to keep it from falling through.

 

Like the proverbial 2 x 4 strapped across your back when entertaining ladies of questionable virtue...