Hole repair

[wrstp]

I recently recieved a split window decklid that is in great shape minus a few unwanted holes so thought I would post how I go about filling them.

As you can see there are a few to many holes and they are not perfect.

I start off by cleaning the holes up with a uni bit or a drill bit. I try to go just big enough on the hole to clean it up. Four of them I drilled to 9/32" and will use a 1/4" plug to fill and the other two drilled to 5/16" and pluged with 9/32".

I didn't have either size in my stash of 20 guage plugs. So out comes the hole punch and a scap piece of 20 gauge. You can also use a piece of left over repair panel to make these plugs if raw 20 guage isn't avaliable. A little hammer and dolly action is required to flatten the plugs after they are punched.

I will use a piece of brass on the back side to hold the plug flush but anything from scrap aluminum to an old dolly can be used when tacking the plug in place. While the tack is still warm I will grind it down and use my hammer and dolly to stretch as well as flush up the plug. Only a couple of hits with the hammer are required. I like to do this for a couple of tacks and take my time as not to add to much heat and warp the panel. As a rule of thumb if you can hold your hand on the metal without burning yourself then its ready for another tack.

Final result should be a nice smooth no bondo required repair. I hope this helps and thanks to all who have helped me over the years.

[wrstp]

Another quick tip if getting to the back side is out of the question. I will drill an 1/8" hole in the plug and use a klecko to hold the plug in place while I tack it. If you don't have kleckos you can use a rivet but only pull the rivet till it grabs the metal. Using the nail of the rivet to hold the plug flush and later drilling rivet out and welding the hole up.

[BusterBrown]

Nice! Good of you to share this knowledge.
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1978 Sage Green Westfalia (Happy Trails, SOLD)
1977 Transporter

Life is short. Can I have some of yours?

[ateneo]

I have been wondering how to plug the holes on the nose of my 1971 Westy.

Thank you for being so generous in sharing your methods. I am sure a lot of VW restorers out there had benefitted and will continue to benefit from the restoration techniques that you impart.

[airedout]

What you did looks great and works. I'm just wondering why you: A - just weld the holes up solid and grind both sides smooth. B - use a piece of brass to back the hole and weld and only have to grind one side. Nothing wrong with what you did, just extremely time consuming for the same result.

https://www.google.com/search?q=matco+plug+weld+to...SawKNJM%3A

This is what I would use for the same repair

[wrstp]

[oldmanmark]

does anybody sell hole plugs?

[Mike Fisher]

We didn't have any trouble mig welding/grinding trim holes on our squareback fenders.
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https://imgur.com/user/FisherSquareback/posts
69 FI/AT square Daily Driver
66 sunroof,67,70,71,71,71AT,72,72AT,73 Parts
two 57 oval ragtops sold
'68 Karmann Ghia sold

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[brywisco]

ditto oldmanmark's question...
Can you buy sheet metal hole plugs in a variety of diameters somewhere?

[kenshapiro2002]

Great stuff...I was wondering how to weld up the holes in my roof from an aftermarket rack (can't get to the back side due to the headliner.

[DJ Bill]

[kenshapiro2002]

Yeah...I was wondering about the headliner catching fire. How would you go "plastic"?

[wrstp]

I agree with DJ Bill don't weld with the liner in and thanks.

[Doug C]