Steel plug kit

[rapid49]

Awhile back I saw a kit with assorted size metal plugs such as what would be used to fill holes in a fire wall . Now I can't find it . Does anybody know who sells these ?
Thanks, Evan

[frankyJ]

Hi rapid49,I think your talking about the weld in hole repair kit sold by bob drake.O think it would be cheaper to make your own but hope it help.

[_Ogre]

since i was carpeting truk i just cut up a piece of 16 ga steel into various size squares
any floor covering will cover up irregularities
i placed all plugs on the inside and welded from the outside

[mr48chev]

They might be a little on the crude side but if you have a drill press you can use a hole saw without the drill bit and make plugs of different sizes. You will have to clamp the sheetmetal to the table of the drill press to keep it from moving and have a wood block under it.
I remember seeing something about the filler plugs somewhere a few years ago but can't remember where and don't remember seeing them again. I think some outfit was punching them out with a punch press.

[dsraven]

here is the bob drake site

https://www.bobdrake.com/FordItem.aspx?Item=HR-1580

they are a little spendy for what you actually get. do you have an electrical shop in your area? the knock out plugs from a breaker box may work.

if you find some that will work but they are too big you can use a step drill to make the hole bigger and also clean up the edges of the hole so it is fresh metal and also round. then spot a nail or a piece of mig wire onto the plug to help hold it in the hole while you tack it in. a magnet will work but disrupts the mig weld so you will get splatter.
what I have done is cut the lower part off a cheap C clamp, so you have the threaded part and the upper and main part of the C. then drill and tap a hole up into the cut off part so you can attach a maget to that part. then you can use the normal threaded part if the clamp to hold the plug in place and the magnet doesn't disrupt the mig weld so much because it is further away. the clamp comes in handy for small holes as well, where you will simply weld the hole shut. you can use a copper pipe cap as a back up piece behind the hole if you slip it onto the end of the threaded part and screw it down so it is flush with the back side of the hole you will be welding.

[dsraven]

or there is this idea


http://www.ebay.com/itm/Magnetic-Hol...-/300986321091


just don't use any plugs that are galvanized. the gas emitted will make you sick.

you could also try a metal fab shop to see if they have a any scrap turret punch plugs. it would be scrap to them because they just punch a hole and the plug hits the scrap bin. if you find a size that is readily available just drill all your holes to that size instead of trying to find a kit with a bunch of sizes but only reall has a few of the size you actually need.

for smaller holes you can use the head of a nail as long as it isn't a plated nail. then cut the part off that is left after your weld is done. you gotta grind it smooth anyway. nails come with a built in holder so they are handy that way, and cheap too.

[dsraven]

if you have an engine rebuild shop or parts place nearby they may be able to fix you up with some disc style frost plug/oil gallery plugs. the hard part will be finding some that are not plated. just flatten them with a hammer before you weld them in. again, drill the hole in the firewall to match the plug size you have readily available.

[OrrieG]

about 45 holes in my dash from small screw to 1.25" Used hole saw to get close, die grinder to fit. Magnet to hold in place to tack. Weld, grind, repeat as needed.

[rapid49]

Those from Bob Drake are a bit too pricy I guess I'll have to make my own . Some good ideas here . Thanks to all that responded.

[mongocanfly]

One suggestion above said get the knockouts from electrical panels..if you go that route don't use galvanized ones..welding galvanize is highly unrecommended...

[59chev]

Try Welder series in Ontario Canada. They call them Unholes.

https://www.welderseries.com/Unholes-p50202282

[1958Warrior]

I just used flat washers that fit the holes , then just plug welded the hole in the washer, the smaller holes I just plug welded shut, the few larger holes just cut some sheet metal to size to fill, grind smooth on outside, don't have to be too concerned about inside no one will see under dash , hushmat and carpet . Don't fill in your holes you 'll need to keep hinge brake clutch ect.

[Dave0]

Harbor freight throatless shear for anything bigger than 3/16 and a few seconds with a small disk grinder then tig em up!

[_Ogre]

for the smaller holes i used a magnet to hold a short piece of flattened 3/4 copper pipe
it worked well

[rapid49]

Thaks everybody . I'm gonna get some from welder series.

[solidaxel]

This may sound different but when I was filling firewall holes
I would go to the hardware store and in their steel nail bin pick up a assortment of nails up to 5/16 and stick them in the holes from the inside, hold them with pliers ,and weld them up, cut them off with a grinder, and add more weld if necessary

For the larger, cut and trim sheet metal to fit the opening

[MiraclePieCo]

Originally Posted by rapid49

Those from Bob Drake are a bit too pricy I guess I'll have to make my own .

Speaking as someone who's fabricated more hole plugs than I can remember, they are inordinately time consuming to make and I'm happy to see these are available at this price.

[hogfarm]

I went to the local iron works and asked if I could get the drops from under there punch,they gave me a bunch

[Scott2]

I'm with Miracle Pie - your time is worth a lot. I bought the kit and I am very happy I did.