The Stovebolt Site Forums The Shop Area Paint and Body Shop Welding up punched holes

Been having some problems welding up punched holes. Last weekend I was replacing the Kickpanels in side the cab and I used a punch tool to make the holes along the edge. When I weld the holes up, I never seem to get the panel to stick to the flange under it. I have the panel clamped tiht and have tried several different settings on the MIG welder. The holes look very good when I finish but when I release the clamp, the weld don't hold. What am I doing wrong?

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