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Thread: How big do you like your holes for panel welding?

  1. #1
    Join Date
    Nov 2011
    Posts
    201

    Default How big do you like your holes for panel welding?

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

  2. #2
    autobodytech43 Guest

    Default

    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.

  3. #3
    Join Date
    Nov 2006
    Posts
    2,135

    Default

    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

  4. #4
    Join Date
    Nov 2005
    Posts
    45,318

    Default

    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.

  5. #5
    Join Date
    Jun 2007
    Posts
    202

    Default

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

  6. #6
    Join Date
    Nov 2005
    Location
    Talladega, Alabama
    Posts
    540

    Default

    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.

  7. #7
    Join Date
    Dec 2011
    Posts
    873

    Default

    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.

  8. #8
    Join Date
    Nov 2005
    Location
    Talladega, Alabama
    Posts
    540

  9. #9
    autobodytech43 Guest

    Default

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

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