How big do you like your holes for panel welding?

[kcode]

I usually use 3/8 inch holes for spot welding my panels together. What size do you guys like?

[autobodytech43]

3/8". I used to like 5/16" and was intimidated by 3/8" but learned how to do clean plug welds, and you have to learn them cause when you reuse sheet metal those 5/16" holes aren't gonna cut the weld out. Either of the two are recommended. 3/8" obviously for more important structural stuff.

[Bob K]

My spot weld cutter is 5/16 so that is what I use most often. With a 3/8 you should get a good weld. I don't like 1/4 or smaller because there is a good chance of filling the hole on the top sheet and failing to get any penetration into the bottom sheet of metal. You may have a good looking weld that doesn't hold the two pieces together. What good would that be?

Bob K

[Len]

I use a 5/16" hole. If possible you should PUNCH the hole not drill because punching will leave the metal surface flat and your seams will be much more level.

[ding]

ideally it would be whatever the vehicle manufacturer recommends in regards to size and number of welds

[SamG]

generally I use 5/16"...1/4" for smaller, more delicate pieces. Only time I use 3/8 is when I'm removing structural pieces.

[junk]

Where do you get a punch that will do 3/8 or 5/16" holes in sheet metal? My cheapo flanger/puncher does 3/16 and they are too small.

[SamG]

http://autobodystore.net/Merchant2/m...Category_Code=

[autobodytech43]

http://autobodystore.net/Merchant2/m...Category_Code=

I just use those punchers for big pilot holes til I get my roper whitney.