can't believe how many little holes are in this firewall... even though my build will skew more towards the 'rat rod' style, i'd like to clean this up a bit (if nothing else to seal cab better).

JB Weld and a grinder?
MIG weld short bolts and a grinder?
'plugs' of some kind?

ideas appreciated, thanks.

 

What was suggested to me was to cut out small sections and weld in new metal. Less chance of warping and a cleaner look. If it is a lone hole then just weld in a piece of metal.

 

I left almost all of the factory holes. I used hole plugs for the larger holes,and button head bolts for the smaller holes. I didn't have to many extra holes but the few I had, I used a bondo product called "plastic metal". Most would say to weld & grind for the smoothest look.

 

avf100

Great idea about the plugs. Thanks for sharing.

 

I also removed the wiper hole

 

For holes that I could make plugs with I used those and then did small tac welds with the TIG. I tried MIG too but found it easier for me with TIG. For smaller holes I use a flat piece of copper and a strong magnet to hold it behind the hole. Then welded up the hole. Again using small tac's to close the hole using a triangle pattern.

I got the copper backer from Harbor Freight welding section.

 

I bought a magnet from Harbor Freight, flattened a piece of copper pipe, fashioned a piece of scrap metal to hold tension on the copper. Bolted it together and you can place it inside over the hole you wish to close up and mig it up. I also built several fixtures for use with this magnet, but bringing photos from photobucket to here is a pain.

 

For the small holes, I used nails with a head about the same size as the hole. Mig welded them in, then cut off the body of the nail and ground them smooth.

Worked for me.

Hope this helps

Dan

 

I like that magnet fixture Drew.... good job.

 

I was at our local HF today but they didn't have the copper backers any more. I'll have to look on line.

 

Great job Drew as the magnetic field does not play well with electric welding.

 

copper pipe flatten it
magnets from donor cars and trucks speakers

 

Thanks for the replies. Those of you using plugs, where'd you get 'em?

 

Yeah, I found out real quick with my first fixture that the magnet cannot be close to where the welding is going to occur.

 

Another fixture that I made for some of the odd situations that I wanted to use a copper backer.