My Willys 3A and 3B Community
3A, 3B, DJ Technical Knowledge Base => "Original"-- Technical Questions, Answers, Observations => Topic started by: BMIC on May 01, 2014, 07:30:31 AM
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What is the best way to fill in a couple of extra 1" and 3/8" holes in the dash?
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What I do is I build up weld all the way around the circumference of the hole, then I start filling with weld. Then i grind smooth using a sandpaper wheel for the grinder, aka flapper wheel.
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For large holes, take a washer that is a bit larger than the hole.� Stick a bolt and nut through it.� Grab the bolt with a vise grip and use a grinder to shape the washer to fit tight in the hole.� Tack the washer in place.� Remove the nut and bolt.� Finish out the welds, then fill the small hole in the center of the washer.� Grind smooth, then sip some lemonade while admiring your mastery.� :)
For the smaller holes, I have used a carriage bolt head, shaped to fit the hole, weld in place, then cut off the threaded part and grind smooth.
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On smaller holes, you can clamp a thick flat piece of brass or copper/brass alloy behind the hole. Then weld it up. Take a hammer and knock off the brass and grind and clean. You have backing that won't stick and no weld mess on the back side. John
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bondo and fiber mesh.
j/k, follow the advise of the greats above.
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Several different ways to cover up un-used holes......including all that are already listed.
1. Quick and easy........put a bolt in the smaller holes.
2. Also quick and easy.........if you are not going stock. Install a switch, gauge cig lighter or another dash light in the holes. If you are making modifications anyway, chances are you are going to need one or the other. Bolt on a cup holder. Go BUBBA CRAZY!
3. For filling larger holes smooth.....I like to make a bigger hole to start with. To do this you need a metal hole saw bigger than your current holes. If you currently have an 1" hole, get a 1 1/4" or 1 1/2" hole saw and cut your hole to that size. Then, take the same hole saw to some spare metal and cut a plug out the same size to use for your patch. Presto! Your patch should fit your hole very closely and just leave enough gap to weld around. Take your time welding and grinding smooth with plenty of breaks to avoid heating the metal up too much and warping it. You should also weld in the plug using a criss-cross pattern to keep it flush in the hole.
Good luck!
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Thanks for the impute guys, always good info.....
GG, I'm not that good with a Mig and Bret, bondo and mesh... can't say it did not cross my mind.
Have a great weekend!
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If you use a flat piece of copper or aluminum held behind the hole, and then slowly MIG weld it closed, it works pretty well.� MIG uses the gas to shield the weld from oxygen and keep it from burning...the alum or copper shields the weld from the exposed rear and helps prevent burning..a flattened piece of copper pipe works....
Practice on a scrap piece of metal...
Like all of us, you will be pretty good at it by the time you are through!
Or, some hardware stores carry chrome snap-in hole plugs..they could be painted....
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X2 on the pipe.
For my dash, which had NINE extra holes ranging from dime to nickel in size, I took a 8" piece of scrap 1" copper pipe and smashed one end of it with a dead low hammer.� Then I bent it to a 30� angle. Did the same to the other end but gave it a 45� angle.� The intact tube in the middle works as a handle, and the angles give me some leverage to keep consistent pressure on the back of the hole.� Worked pretty well.
I can see using a variety of pipe diameters to make a few "spoons" that will fit where you need them to go.
Depending on how long you are at it, be careful of the heat that can transfer through the copper pipe to your fingers.
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My dash had MANY extra holes.
I have been finding things to put in those holes (fuseholders, switches, etc.) rather than hide them.
Of course the dash looks FAR from stock because of all the extra things.
:P