Auto body repair & detailing: 67 malibue cowl panels, spot welds, seam weld

Question
hello

Just wondering about filling the holes in the panels. I drilled the spot welds with a 5/16 bit. I relize now that one panel will have to be filled for plug welding. I have not seen replacement panels yet so filling holes i go. I tried using copper as a backing to plug weld. I was using 0.035 wire, may be i need smaller wire and mig machine? These attempts did not work so well. The metal got distorted. I cut the edge off hoping to butt weld the 1" strip back on this is were i stand now.

Answer
Harold, you offically made a mess. You should have used spot weld cutters as opposed to drilling thru both panels. I'm guessing you're using flux core mig wire- it's really too heavy to weld sheet metal. (takes more heat than .23 gas shielded wire) You can try to move down to 30 thousands, that will require less heat. Welding sheet metal is difficult under the best circumstances- expect warpage. Only do a couple zaps at a time, only do half inch stitch welds- don't seam weld. bounce around, be patient, you'll get it. Bill