Suggestions on filing these holes in the engine compartment sheet metal - Vintage Mustang Forums
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post #1 of 15 (permalink) Old 09-12-2019, 09:02 AM Thread Starter
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Suggestions on filing these holes in the engine compartment sheet metal

Looking for suggestions on filling these holes in the engine compartment.


Would you weld in a piece and grind it down? Since one is close to the fender, would the fender need to be removed due to potential heat damaging the paint?
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post #2 of 15 (permalink) Old 09-12-2019, 09:08 AM
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I would un-bolt the fender and slide a piece of heat-resistant material between the fender and apron and then up and over the fender as a "splatter guard". Use a copper "spoon" behind the hole and weld up from the outside inward.

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post #3 of 15 (permalink) Old 09-12-2019, 09:09 AM
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2 options I would consider:

1) Remove the fender, weld up the hole, repaint and re-hang your sheet metal.

2) Put a bolt in each hole. 9 out of 10 people would never notice or question the bolt.
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post #4 of 15 (permalink) Old 09-12-2019, 09:28 AM
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Quote:
Originally Posted by ivygreen65 View Post

2) Put a bolt in each hole. 9 out of 10 people would never notice or question the bolt.
Since your car looks fully assembled and running, I like that option a lot.

The front of my car is all torn down. I spent a bunch of time filling similar holes all over the place. My technique for those 1/4" holes: drill it out and tap it to 5/16-24. Screw a bolt in there, just far enough to grab threads. Cut it off with an abrasive wheel. Tack weld it in, grind it flat. Skim some filler on there if needed. Paint the back side too.
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post #5 of 15 (permalink) Old 09-12-2019, 10:17 AM Thread Starter
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2 options I would consider:



2) Put a bolt in each hole. 9 out of 10 people would never notice or question the bolt.


I went to my first judged show this past weekend. I was basically taught a lesson.
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post #6 of 15 (permalink) Old 09-12-2019, 10:34 AM
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You probably could fill the hole with Quik Steel, mask, sand smooth and paint. If you may need the hole again for something, put a nice rubber grommet or plastic push cap in it.

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post #7 of 15 (permalink) Old 09-12-2019, 10:38 AM
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I only know one answer to all metal questions: Weld and grind, and yes, I would remove the fender...you will be glad of the extra room...and yes welding that close will almost certainly make the paint on the fender mounting lip bubble and possibly even catch on fire....though its usually seam sealer that catches on fire before anything else.

P.S. You dont need to weld in a piece...just fill it with weld(assuming you are using a TIG or a MIG this is easy...I wouldnt attempt the task with a stick welder though unless you are experienced with it...filling holes with an ARC welder is trickier than the others, definitely one of those situations have an extra hand on the stick comes in handy...with very heavy gloves of course)

Last edited by wicked93gs; 09-12-2019 at 10:43 AM.
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post #8 of 15 (permalink) Old 09-12-2019, 10:42 AM
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find a washer the size of the hole hold it with a magnet while mig welding it in, grind putty sand paint ect


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post #9 of 15 (permalink) Old 09-12-2019, 10:50 AM
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find a washer the size of the hole hold it with a magnet while mig welding it in, grind putty sand paint ect
Sure...if washers didn't have holes. To be fair though you could possibly find one with a small hole...but finding a washer that small to begin with is going to be hit or miss. you could however cut a piece of scrap steel and use a magnet to hold it under the apron while filling in on top of it...a little bit easier than filling empty space.
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post #10 of 15 (permalink) Old 09-12-2019, 10:58 AM
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Quote:
Originally Posted by wicked93gs View Post
Sure...if washers didn't have holes. To be fair though you could possibly find one with a small hole...but finding a washer that small to begin with is going to be hit or miss. you could however cut a piece of scrap steel and use a magnet to hold it under the apron while filling in on top of it...a little bit easier than filling empty space.
I hole that small is

to fill with a mig


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post #11 of 15 (permalink) Old 09-12-2019, 11:07 AM
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A bolt would be Soooo easy,....

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post #12 of 15 (permalink) Old 09-12-2019, 11:17 AM
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Easy? What is this word? I dont understand it, its not it my dictionary. I agree, I would throw a grommet/plug or a bolt in it unless the car is being judged or you really just want something to fix.
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post #13 of 15 (permalink) Old 09-12-2019, 11:28 AM
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The correct way is to cut sheet metal into little disk "plugs" that fit snug. If you have tig you can easily control the heat or with mig just make little spot welds all the way around. Get a piece of cold rolled sheet metal or scrap and drill some holes then practice filling them this way. Get your welder settings figured out on the tests.
No need to remove any sheet metal, just protect your parts from weld spatter. Especially cover the glass! Take your time and cool the welds with a damp rag as you go if it gets too warm. Be sure to prep to bare metal around the holes first of course. A little wipe with body filler, finish out and your done! Be sure to finish or seam seal and paint on the outside too as otherwise water will migrate into your bondo and blister up on the inside.
This is a 15 min fix, I have been building custom cars and a professional paint and body man since the late 70's and have done more of these than I can remember...
That said, on my personal car that is not too pretty (a cobblers child wears no shoes) 😁 I would probably just throw a bolt in it. If my car was finished I would repair it correctly.

Last edited by Matter; 09-12-2019 at 11:34 AM.
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post #14 of 15 (permalink) Old 09-12-2019, 01:30 PM
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Got a mig? I'd definitely weld it. You'll have to take the fender loose for sure.
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post #15 of 15 (permalink) Old 09-13-2019, 10:10 AM Thread Starter
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Never welded. Going to go get a Mig set up at the end of the month, and practice. Thanks for the tips, especially the recommendations to prevent splatter from hitting any glass and how to protect the fender from the heat.

15 min fix? HA. never had that experience with a mustang
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