Hi Whitney,
I read an article on filling holes in the frame, which basically said to do
what you have in mind. They cut plugs from mild steel rod with a chop saw.
Before they pushed them in, they used a carbide cone bit in the holes to
make a valley for the weld so that when they were ground flush, there was
still a solid bond.
If you're working in sheet metal, they recommend that larger holes (larger
than about 5/8, I guess), should have a sheet metal plug inserted. The
punch or snip the plug to size, then hold it in place with masking tape
while tack welding it in.
Regards,
Grant S.
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