Morepower16,
The welder has to turned up more than one would thing and the hole has to be larger than expected. If you start a nice hot puddle in the middle of the hole, melting the base panel, then let the puddle wash to the edges of the hole in the replacement panel, it will stick like glue.
If your welder is turned up sufficiently, the whole thing will be almost flat and need very little finishing. The panels must be held tight against each other and it imperative you melt the material in the base panel first.
The holes must be large enough, at the very least 3/8" and all the surfaces must be clean and rust free.
Practice on some scrap first. When done properly, the welded spot will look like a red hot button until it cools. Good luck!
Stuart
Last edited by atomarc; 07/12/2008 4:18 PM.
