How to fill molding holes

[D-rock1981]

Figured I would try and contribute something to the forum for what it's worth. I'm doing this all from my phone so it may or may not work! Lol. I work at a hot rod shop in Denver, and this is how I fill up molding holes.

Here is the hole we're going to fill. This is on a Plymouth fury. Using a scotch Brite roloc I prep the area and drill it out slightly bigger to fit the plug we're going to use to fill it.


This is the punch I use to make the plug


The punch creates a divot in the plug. I set it on an anvil and tap it with a hammer to flatten one side. There will still be a small divot on the other side. This is the side that goes out.



I use a piece of tape on the backside to hold the plug for a quick tack. It does burn the tape, so be quick.


One quick take. I remove the tape, then using a hammer and dolly I will tap the plug and get it flush.


Next it's welded up. I tig weld, but mig or gas is also acceptable. Just remember when mig welding it will be hard to hammer and dolly to a metal finish. The mig welding wire is harder then the surrounding metal and is prone to cracking. Remember that divot in the plug? Put a little tack on top of that to fill it up. I do this because I found when putting the plug in the other way the metal got way too thin in this area so I like to fill it up with weld.


Next I use a 60 grit roloc to knock down the weld. I don't take it all the way down, notice you can still see we're the ends of the weld are.


Next I will planish out any distortion with a slapper file and a dolly. Then finish with a scotch Brite roloc.