Like everything else in this world, there's a right way and a wrong way to handle metal repairs. For instance, if you're installing a patch panel into a lower cowl as we're doing here, then hammer welding is the right way to do it so that the patch literally becomes one with the original panel. Practiced at the high end of the automotive repair business, it's a little more time consuming than your average patch-up, but don't let that put you off. If it's good enough for a Rolls Royce, it's good enough for your project. With practice, your efforts will result in a weld that your buddies will be hard-pressed to spot, and not because you slathered it in Bondo and high-build primer before they arrived. A good hammer-weld will bond two panels using next to no filler rod, and the seam will all but disappear when you run the sander over it. Don't believe me? Just watch as Kerry Burch at Limeworks Speedshop wields his magic wand.
Although not for the inexperienced, hammer welding is still just welding, so don't be intimidated. If you're confident with your gas torch, get at it. By the time you're halfway through your roached project body, you'll be surprised at how good you've become. Just remember: Think ahead, anticipate the metal, and most important of all, take your time.
