Here are my best tips and tricks to fill holes in thin sheet metal! Of course it's not easy on thin 20 or 22Ga steel, but I feel like TIG Welding is the only way to go because the welds can be easily plannished to remove distortion. MIG might work with lots of grinding and bondo, but at least for my car I think TIG is much more elegant. I know this project is only engine tin, but it many ways its harder because the parts are so flat and cumbersome.
My welder is the primeweld AC/DC TIG -
https://amzn.to/3QgTEvTIt's a great machine and I highly recommend it.
My in person welding class is Feb 19th, 2025 in Huntington Beach, CA 9-5 pm $225
You will learn the basics and improve your results guaranteed. Reach out to me via email if you are interested in the video tutorial course which includes behind the helmet shots.
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https://www.ahhgaragetime.com00:00 How to Fill Holes in Your Engine Tin
00:56 Porsche 911 Heater Duct Routing
02:57 Remove Paint with Strip It Disc
04:17 Mark Patch Panel with Sharpie
04:58 Trim Sheet Metal To Scribe Line With Snips
07:01 Check For Tight Fit Prior to TIG Welding
07:47 Form Indent with Lead Shot Bag
10:20 Add Definition to Formed Indent with Hand Tools
12:16 TIG Weld Patch In
17:54 Watch for Distorion and Push Metal Back as Needed
21:20 Remove Distorion With Hammer