Extra Holes in tub

[da_man1974]

So I took the top off my 43 last night. I am assuming I also need to take out the roll bar as well. This is going to leave holes in the tub from where it was mounted. How do you guys fill these holes? Or do you just leave them?

[Farrell Fox]

[Post Deleted By Author]

[da_man1974]

I have a small wire feed welder.
So I just fill the hole with welds and then grind down?

[1943Willysgpw]

Yes. Do not overheat the sheet metal.

[W. Winget]

Well I had 44 extra holes in my '42 GPW, no Mig at that time, but a stick welder and Gas setup. The gas actually became easier after time to work with VS. the cheesy 110V stick setup I had from a flea market (there).

If you use a Mig welder (easiest, and cleanest with gas shielded wire) Grind the paint and rust away on the panel thoroughly, put a good piece of flat copper behind the side you cannot grind covering the hole. This will allow you to fill them quickly without driving wire through the hole and chasing the edge, it will be rough on the copper side, but not require grinding to flatten it. Then after welding, peel the copper off the back (it should drop free if it's clean copper) and grind the weld smooth on the side you can get to.
A piece of copper house pipe with an end flattened works fine, and provides a handle on one end, which can be shaped to reach the back of the holes.

And if using gas welding, turn on some music and relax watching the oxidization sparks fly as the metal turns orange then fill from the bottom up. Satisfying, period correct repair, but you will have to grind both sides, and panels may squirm and shrink from the heat. (removed the 1" deep floor depression and deep top fender dents using the gas torch, nice and smooth after a lot of heat and wet sizzling rag applications to shrink the metal)
V/R W. Winget

[Old Pal]

Depending on the size of the holes, I’d cut a plug and weld it in or use a copper plate as a backer for small holes, similar to this:

6F0A42C5-EFE7-4BCD-9ECD-61F15093F641.jpeg (21.44 KiB) Viewed 145 times

[da_man1974]

So the copper plate thing is just so I am not blowing out the bottom side correct? Basically keeping all the molten welds inside the hole?

[Old Pal]

So the copper plate thing is just so I am not blowing out the bottom side correct? Basically keeping all the molten welds inside the hole?

Essentially, yes. It will give your weld some structure on the bottom side without blowing out the hole and it is material that won’t stick to your weld.

You don’t have to buy expensive copper plates with magnets. I’ve used scrap copper and flattened copper pipe.

[da_man1974]

Ok. that sounds like a plan

[JAB]

So the copper plate thing is just so I am not blowing out the bottom side correct? Basically keeping all the molten welds inside the hole?

basically, yes.