How To Weld Gaps In Sheet Metal

Andy gives helpful insights and tips to mig weld thin sheet metal.

How to weld gaps in sheet metal.

Make the replacement metal is not larger than the original metal or it will not fit. Working in short bursts will form a bridge between both pieces of metal. Tack welding is the best way to hold the metal in place before you fully weld it to the original metal. When mig welding a patch panel on your car body panels you should think of leaving small gaps between the patch panel and the original metal.

The best two electrodes for welding auto body sheet metal is either ceriated tungsten or thoriated tungsten. Ditch a 1 8 inch tungsten electrode for something much smaller like 1 16 inch tungsten. My names matt urch and i own and run urchfab welding and fabrication. Here s a little trick i use when i come up against a gap that s a tad to big.

Tack weld in place. I keep blowing through my thin sheet. Take the time for proper fit up proper tight part fit up is especially important when welding thin materials. How to mig weld large gaps the right way corners.

Tack welds are simply small welds that barely penetrate the metal and aren t pushed or pulled to form a bead. During the welding process the metal will get hot and the gap a welder leaves will compensate for the expansion that occurs. Use short bursts when you weld. It doesn t matter as much it it s a bit smaller because if there s a very small gap this can be filled with filler metal.

A 100 argon shielding gas is the most common in mig welding aluminum sheet metal. For even thinner materials try a 035 inch filler metal.