Rusty Thin Sheet Metal Blowing Holes Welding

The photo is 1mm steel welded at a power setting normally reserved for 2mm steel.

Rusty thin sheet metal blowing holes welding.

The butt weld page showed how to do a seam weld using a continuous torch movement. The easiest holes to fill are small holes about the diameter of a pen or smaller. Make sure to use an electrode wire that is thinner as it uses lesser heat and prevents blowing holes on to the sheet metal. This is the thinnest sheet metal i have ever welded using this process.

Video of the day. The complexity of welding increases as the thickness of the material decreases. For these types of holes i start by cleaning the area around the hole with an angle grinder and flap disc. Stick welding sheet metal with 6013 rods.

The most permanent repair to a hole in sheet metal is to weld the hole shut. Try going for a wire of 023 inches when welding sheet metal. I m welding very t. Try applying that technique to steel less than 1mm in thickness and you are likely to blow a hole in the metal.

A rust hole compromises the structural integrity of the metal. Two part epoxies are designed for this purpose and when applied to a clean surface the final repair will be undetectable after painting. Any kind of welder can be used but the best results come from a competent repairman using a tig or mig welding machine. Try welding with a scrap sheet metal piece and practice many times until you start working on more important projects.