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Old 02-07-2020, 06:54 PM   #26 (permalink)
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ESAB EZ grind in 0.023
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Old 02-08-2020, 01:58 PM   #27 (permalink)
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Had a welding instructor show me to use flux core wire with C25 gas for thin metals. Produced super nice welds.
Haven't done it in years though.
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Old 02-11-2020, 09:59 PM   #28 (permalink)
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I need to fill 20 or so screw holes, maybe 3/16" in the rockers and lower panels of a pickup that had old man fiberglass running boards.

Doesn't need to be perfect, just getting a $500 paint job and a for sale sign.

I don't have access to the back side for a piece of copper

I have a big mig with .035 wire, and a little 110v with .030 flux.

I have a couple welding rods I was thinking of using as filler, redneck tig

I could also plug them with bondo worms

Suggestions?
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Old 02-11-2020, 10:22 PM   #29 (permalink)
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Originally Posted by PROJECTJUNKIE View Post
I need to fill 20 or so screw holes, maybe 3/16" in the rockers and lower panels of a pickup that had old man fiberglass running boards.

Doesn't need to be perfect, just getting a $500 paint job and a for sale sign.

I don't have access to the back side for a piece of copper

I have a big mig with .035 wire, and a little 110v with .030 flux.

I have a couple welding rods I was thinking of using as filler, redneck tig

I could also plug them with bondo worms

Suggestions?
Button head allens

What kinda truck? Toyota tin can thickness or older full size? Toyota thickness is tricky. Can you put your regulator and bottle on the 110v and get some 023?
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Old 02-11-2020, 10:22 PM   #30 (permalink)
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Originally Posted by PROJECTJUNKIE View Post
I need to fill 20 or so screw holes, maybe 3/16" in the rockers and lower panels of a pickup that had old man fiberglass running boards.



Doesn't need to be perfect, just getting a $500 paint job and a for sale sign.



I don't have access to the back side for a piece of copper



I have a big mig with .035 wire, and a little 110v with .030 flux.



I have a couple welding rods I was thinking of using as filler, redneck tig



I could also plug them with bondo worms



Suggestions?
Nails can work well for this. Place head in hole. Spray some weld around. Cut/grind it smooth.

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Old 02-11-2020, 11:33 PM   #31 (permalink)
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Button head allens

What kinda truck? Toyota tin can thickness or older full size? Toyota thickness is tricky. Can you put your regulator and bottle on the 110v and get some 023?
Maybe, but I'd still need filler metal right?

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Nails can work well for this. Place head in hole. Spray some weld around. Cut/grind it smooth.

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This is a pretty damn good idea
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Old 02-12-2020, 09:43 AM   #32 (permalink)
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How about rubber/plastic plugs?

No welding or painting. Just For Sale As IS and move on with your life.
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Old 02-12-2020, 07:31 PM   #33 (permalink)
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Maybe, but I'd still need filler metal right?
Meh, 3 or 4 tacks should do it.
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Old 02-12-2020, 07:48 PM   #34 (permalink)
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Brazing sounds interesting but web search said I need pure Argon it will be a while before I can fill an empty tank with it. Ill probably give 023 a shot in the meantime.


braze with an oxy-fuel rig and flux. low heat, softer stuff.


I can't think of a good reason to tig weld with the nickle bronze stuff. seems like a pricey adventure and the electric heat is still pretty high. it does flow nice though
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Old 02-12-2020, 07:51 PM   #35 (permalink)
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Originally Posted by PROJECTJUNKIE View Post
I need to fill 20 or so screw holes, maybe 3/16" in the rockers and lower panels of a pickup that had old man fiberglass running boards.

Doesn't need to be perfect, just getting a $500 paint job and a for sale sign.

I don't have access to the back side for a piece of copper

I have a big mig with .035 wire, and a little 110v with .030 flux.

I have a couple welding rods I was thinking of using as filler, redneck tig

I could also plug them with bondo worms

Suggestions?
bondo worms would be the easiest thing.

i'd do that, and have done similar, with 0.030 flux core. go slow, seems like about half a loop is the max in one pull. just take your time and work around, eventually it will fill in the hole, sand it back down as you see fit
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Old 02-12-2020, 09:46 PM   #36 (permalink)
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I need to fill 20 or so screw holes, maybe 3/16"
Small flat washers with an aluminum pop rivet in the center hole to have something to hold it in place while you tack it. Don't install the rivet, just use it to hold the washer in place. Tack it, remove the rivet and fill the center hole.
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Old 02-12-2020, 11:22 PM   #37 (permalink)
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Another believer in 110 for thin metal. Auto body shop says only 110. My miller 218 or something could never do the thin stuff on 200Volt. I bought the convertible 110/220 unit and never looked back.
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Old 02-13-2020, 07:40 AM   #38 (permalink)
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I've had no problems doing down to 18ga with my Hobart Ironman 210 with .023 solid wire. Haven't had a need to do thinner than that.

Last edited by GLTHFJ60; 02-13-2020 at 07:41 AM.
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Old 02-13-2020, 08:22 AM   #39 (permalink)
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buy the smaller wire, use a backing strip if you can so that it is twice as thick and/or use a heat sink.

I've done had good luck with zap....zap....zap....zap stuff to fix holes and cracks and such in cars. just a matter of going slow, lower heat, fast enough wire.
What is the best material to use when it is used as a heat sink?

Copper, brass or aluminum? something else? Thicker is better?

My 1985 CJ-7 has duplicate holes drill in the tub that I want to weld up in the future, when I pull the tub off and go through everything with a fine toothed comb. Apparently it had two different soft tops installed in its previous life.
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Old 02-13-2020, 11:08 AM   #40 (permalink)
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yes, copper/brass would be better than aluminium, but AL works also. thicker is better until it won't fit where you need it to. even 1/8" would be helpful for doing 18 or 20 gauge.

I've used 1" steel as a backer for 1/8" steel before. kind of depends on the setup but the idea is that you are welding on low enough amps that you aren't going to appreciably bond to the backer. copper is dis-similar so it naturally doesn't want to bond to steel, just so long as it is thick enough that it can dissipate the heat
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Old 02-13-2020, 04:43 PM   #41 (permalink)
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I just used my Hobart 140 last night to weld up a fuel tank for my buddies F800. 0.023 wire and it was awesome. I forgot how nice it is to be able to 'burn' a weld in without blowing through thin stuff.

Best $500 I ever spent on a welder, esp since the first job I did with it paid $600!!!
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