Filling small holes without welding

[dragstews]

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Welding is most likely the best way to go about it ..

 

[Bennyt]

I would only weld, everything else is a compromise and cross your fingers it is going to last.

I use these plugs from Speedway and others for holes larger than 1/4". Unibit to size and a magnet to hold. Saves a lot of time. Available in various diameters and gauges.

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[bucket]

If the holes are actually only 1/8 or 3/16-ish in size, it's pretty easy to weld those up.

It was mentioned earlier, the possibility of using fiberglass body filler, along with dimpling the steel down. Imho, it's the next best thing to welding. Simply grind the metal a bit, ding it down, feather the surrounding steel with 80 Grit on a DA, then apply the Duraglass. Sand the Duraglass down a little "too far" and skim coat with a polyester glaze.

It may be considered a little bit "hack" this day and age, but it does work very well.

 

[Doppleganger]

I used a stud welder. Stud is tapered on the end - 1/16 to 3/16. Holes are 1/8 (2/16). Set the stud in the hole and lit it up. Snipped the stem, ground the nub down. Nice little welded copper plugs.

Still have 2 large holes on the firewall - ground down some fender washers to make perfect plugs - now gotta get it tacked in. lmao - will never happen around here. Maybe I can get creative with panel adhesive?

 

[Steelbuddha]

If you've got an oxy acetylene outfit I'd braze them shut.

Agreed.

 

[Oldbear42]

I have a redneck copper spoon for welding holes in sheet metal. It's a 1" copper pipe flattened and folded, then attached to a handle. I also have the spotweld clamp version (store-bought). It keeps the weld flatter and gives a backing and heatsink to avoid blowouts. I need to take the copper to my blacksmith friend so we can heat and hammer the layers together better - but that is a winter project/visit. The picture is a store-bought version of the spoon, but you get the idea (mine is at home).