TIG Welding Tips & Tricks – How to Fill Holes in Metal – Eastwood

TIG Welding Tips & Tricks – How to Fill Holes in Metal – Eastwood


ok everybody it’s matt from eastwood company were here doing another live technical demo here in eastwood garage for any you guys that haven’t watch one of these before we want this to be as interactive as possible we want you to log on chat comments ask questions we have Randy over here there’s a lot of our videos as well Randy’s doing the live chat he’s answering some questions live for you guys he’s also roast them over to me the topic today is going to be in the realm of take welding we’re going to get into a little bit of intermediate stuff here we’ve done a bunch of videos if you haven’t watched them before record as well as live doing TIG welder set up to water basics how to run a puddle and we’ve had some requests for doing some more intermediate type stuff for you’ve got a puddle down but you’re getting into some more different circumstances that are much more difficult so today we’re going to be covering is filling holes in aluminum which is a little bit difficult can be tricked so what I’ve run into a lot is doing wheels and this the same aspect the same situation be put into doing crack repairs and things like that doing aluminum wheels Tommy about covers water necks things like that on an engine that could be cracked or damaged or maybe somebody drilled a hole and apart previously and put a threaded long or something in it that you don’t want you want to take it out you want to fill the hole up clean it up make it look like original again i’m going to show you how to fill a hole up using the TIG welder is a pretty Queen way to do it and there’s a little bit of trick to it so we’re going to do some underhood welding so it will have Joe come over that’s filming and he’s going to put a special lens over the camera so you guys can see what it looks like under the hood pretty cool stuff so for machine setup what we have here on our welder we’re using of course our East would take 200 ACDC it’s pretty tried-and-true what we have here on the the guests I’d so hot % argon and we have one of our flow meters on here are machines come with i’ll try and turn this so you can see what this is our big water bottle but we have a style here that has two round dial gauges on it that’s what our water comes with standard but if you want to upgrade and get something that’s a little more accurate and you actually see what the flow of your machine is when you’re welding and get one of these flowmeters we have them on the website that you can order and you can upgrade this to your world and what this does I’m gonna flip this on I’m gonna hit the pedal and Joe’s gonna film over here you can see the little now there’s a little ball that floats up in here during that time and tapers down when it turns off so with this you can hit the pedal actually see what your flowing and you can turn the little knob here to get higher lower no I haven’t I’m gonna hit one more time I haven’t turned up pretty high for what we’re doing today so it’s getting up 25 ish range is what it’s getting up to the cfh so normally when I’m welding a sheet metal worker or just a normal butt weld I have a turn down to say 15 or something like that maybe 18 that works pretty good but we’re doing today we’re trying to fill a hole in a big area really need a lot of gas flow that’s going down into the hole that we’re filling so I like to turn to guess up you’re going to waste more guess it’s better than having a porous well that’s going to be weekend and it costs pits and it is going to come back the other thing i’m using here is I have a guest lens kit connected to the other the TIG welder to the torch this for what we’re doing today I would say is pretty much a necessity need to have a gas lens kit gasps lens kit has a screen in here you’re not familiar as the screen here that puts a pool of gas out basically fogs the area that you’re welding it’s much more efficient better coverage than a the traditional style that comes with the machine is standard the guests lens kit is going to be a lot better to cover a better area and for what we’re doing we want as much guess coverage as we can get some of the flow turned up and a big-ass lens with a big nozzle a fairly large nozzle on it that’s going to cover a pretty good area so we should keep the world as clean as possible so what we’re working with over here we’re going to jump right into it here shortly is we have a piece of women here I drilled some pretty pretty large some pretty large holes into it so we were getting a machine setup i did one real quick just to do the first pass the feeling that put can see these holes we got a pretty big this is a hole that you know I’ve seen what like a water neck or something like that where someone has you know drilled a hole for a bong or for whatever reason you know this is a pretty large hole this is this getting pretty difficult to fill a smaller hole you can do much easier and quicker but the way i’m going to show you here you can use it you can do it on smaller hole or larger hole it doesn’t matter but I’m kind of taking it to the extreme here having a pretty large hole now this is about the most i would fill if i can get to the backside of this because we can fill from both sides if this was something where I couldn’t get to the back side of it so I didn’t feel confident that I could get a nice a good weld on the backside I couldn’t get my filler rod to fill up that hole what you can do is you can machine out or you know with the whole solar whatever whatever you want to use to make a slog or get round bar make a slug that you can sit into this hole that’s going to be recessed a little bit and it’s a real nice tight fit and then you’re basically you are welding that slug into the hole and then clean up maybe an eighth inch gap or anything sri cess with your filler rod that’s one way to do it if that’s something I couldn’t get into the hole to get to the back side i would do something like that that’s a nice press fit it just gives a little more security but i’m gonna show you on this piece here we’re going to assume you can get the backside say it’s a wheel or something where you can get to both sides you can do this and something it’s you know not super thick that’s something that’s really thick you are going to have to put a slug in it and weld weld the slug in not going to filter on all the way in so that’s where working with that the machine setup of course it’s on AC welding aluminum the other thing here is for what we’re doing i have the clearance effect set a little more towards the positive side so i’m not going to say that it’s in the positive it’s just more towards zero so I have it around negative 2 i would say maybe negative one and a half in that range if I was really nice clean aluminum we’re doing a butt weld and I wanted a real tight arc I probably have it turned up more like negative 3 negative three and a half something like that where the metals real queen and I’m using a guest lens but because we want i want a larger arc so i can heat a bigger area to kind of fill that hole up I have a turn just a little bit more towards the negative side I’m sorry more towards the positive side so the more you go towards the positive side the wider your arcs going to be it’s going to heat up a bigger area but mainly what i want is it’s going to clean a bigger area so I want to basically Queen around that well but you’re going to see we go into the helmet before i start actually about laying any filler rod so that’s why i haven’t turned closer more towards the positive side or more towards zero i also have the pre and post flow cranked up higher than I normally would so I have some pre flow cranked up 2.4 seconds approximately just a little under around there what that’s doing is that’s giving me an extra fraction of a second almost half a second of shielding guess it’s around the weld area before actually striking are just trying to do everything I can to keep it clean so I’m getting getting shooting gets in there before even striking are the post flow i haven’t turned up pretty high at four seconds what that is after i’m done welding i’m going to slowly let off the pedal and I’m gonna let gas flow over the world and i’m turning up a little higher than I would normally because we’re going to be hitting up a big area and shovel autofilter aden so it’s going to tend to stay soft molten or it could get impurities much easier so by doing this we’re putting we’re keeping guess blowing over that hot weld for a longer period of time normally I’d probably have it down here like two and a half three seconds but I want that extra second or so of shooting gas just to try and help me as much as i can so that’s all I have the machine setup on the pedal this is our new rocker pedal for the eastwood take 200 little more ergonomic you put your foot in the bottom here and and it’s a rocker style i have the we have an adjustment here on the side of the pedal so when using the paddle you can adjust on the fly right on them on the pedal so I haven’t turned up to about let’s say a hundred and twenty hundred and thirty amps for my max so when I’m mashing on that pedal that’s what I’m getting so I’m probably not going to use that full hundred 30 amps very much except at the very end but i want to have it there just so I know that when I want to punch the the the pedal down i got that averaged kind of goose it and give me some more some more heat into the piece so that’s my machines set up any questions we have before i start doing somewhere alright so you have any questions shoot over have some time afterwards but I’m gonna make this short and sweet not a lot of talking more doing so I got my holes filled up here i’m gonna do this one here now one thing I am I did it ahead of time but i’ll show you guys did this ahead of time a little bit but when you’re doing these holes filled the whole you want to clean the area as good as you can with a sander grinder scotch-brite anything like that the other thing you want to want to what actually inside the hole that’s the part that I’ve seen that people often forget you got to get inside that hole so what I like to use one of these burb it’s that we sell a tapered burr carbide burr and what this does you can get in there move it around and clean up the inside also I’ll do this one again just to be safe I’m not going real fast just not taking a lot of pure off I’m just trying to clean and get fresh metal in there especially if it’s a the whole you’re filling it’s an old haul somebody was you know there’s made a long time ago and you haven’t gone back through it you’re you’re taking off that layer of oxidation in there by hitting it with the with that day I did I’ve done before a couple of times actually has wheels to have like beadlocks they were putting them for like drag racing on someone one of the holes filled they want to put their own a new set of bead locks on them we had to fill all these holes the holes were already there so what I ended up doing is actually upsizing the holes so took the drill bit went to the next size up and just drilled the holes actually a little larger on every single one that just made sure that you get clean metal let’s turn up with metal its oxidizing has dirt ground into it so it’s best to do that so that’s a good little tip for Queen ahead of time so I’ve already hit this panel with Arlo v OC pre scotch-brite paper towel everything to wipe it off so ready to start welding alright whenever you’re ready Joe I’ll get a get set up here i’m using a year and a half I broke a piece of filler rod in half since these are pretty large hole we’re filling i’m using a a 3 30 second filler rod 3 30 second electrode the III left rotor tungsten and i’m using as a nice stability for welding and i’m going to use in vista to kind of fill the hole here now I’m gonna have to go around so little more movement so just so you know I’m not going to hit you later alright you know when you’re ready alright so i’m going to do is I’m strike an arc and what I’m doing is I’m cleaning I barely have the pedal threat you can see all that oxidation it’s it’s cleaning off I’m kinda going through and almost doing a pre heat if you will and cleaning the oxidation off as much as I can all right i’m gonna start right here where you start doesn’t matter it’s just what’s comfortable for you get a little more throttle it starts to turn molten they’re trying work that edge I’m pumping the pedal just to fill that edge up a little bit and trying to overlap some of my weld into the center you can go this is a pretty big hole would have to go around a couple times here now I got some heat into it i don’t have to actually I’m going around starting to fill up now when i get about whether the whole like this i’m going to punch the pedal steel rod soon as i see it fill up like that i’m going to let off blend the area and one more last dad and I’ll real slow going to come to the side here let off that gas flow ok so i added a lot of filler rod to that we’re going to the backside as well so get again so i will show you after i’m done here the two sides but this side here you can see right now actually the lens on but I basically fill that hole up all the way when I punch that pedal it kind of caved in that extra well that was putting on the edges and then i added Phil arrived to kind of fill all up in one shot full amperage and now what I have this is the back side of the world here on the backside of the world actually have too much material on the backside which is good so you want to be able to take some off and make that whole invisible so the backside of the world since there was no gas flowing on that weld there is some contamination on just the topmost layer because there wasn’t any gas flowing up from behind so we want to hit this stainless steel brush and what I’m going to do is I’m going to eat this area up with the torch and kind of start blending in and if I need any extra material as a fair amount there so I shouldn’t have to add too much but I’m going to keep some rod in my hand just in case i’m going to fill up just on the edge here all right ready alright so same thing we’re going to kind of go over the whole area trying to get it cleaned up its outer edge of the hole remember we have in queens with the fourth yet some sweat news alternating current just dance around and clean for its clean clean clean there in the center and I’m starting to add more amperage using my filler rod out of the center right now but it’s real close just in case you need it going to melt it in now listen up getting some more effort I’m going to move that puddle over i just moved it over and out blend it and fill in the hole I’m letting off a little bit of filler alright so we got this side is the backside of the whole year no you good we got the back side of the hole here filled up you can see the white halo that’s around that I halos cleaning area is much larger than it would be if you just kept your hand in one spot I kind of danced around torch to just get me a nice clean area so if my weld kind of flows out it doesn’t flow out in and go into metal that wasn’t queen in his dirty i’m going to flip it over alright so we’re going to have this is the other side here so what I would do now that this whole perfectly is I’m going to hit it with the sander and a little bit just to knock that little bit of extra off and then we’ll see where we’re at and we may have to go back just a little bit so yeah set this down and then we are going to use the grinder here real quick just to hit this area and this lightly hitting it just to knock down any High stuff I’m trying not to dig into much with the with the sander I just want to knock that the High stuff off so right around this edge here this and this this is the front side i have a little crater which is probably out actually at the edge of that hold on the outside of the whole but just from the land needed to fill we have a little creator there so don’t expect you can always do that one shot and one pass you can fill it it’s a small hole sure you could probably fill in one shot would have been a lot quicker but because it’s a pretty large hole we’re filling here i’m trying to fill it on both sides when we may have to come back so I hit that with the sander but they’re still in that crater there there’s probably some oxidation that occurred just from its sittin here I’m gonna hit the area with a fresh stainless rush that I used only on aluminum and dig in there Vincent would like to know if you could use the copper backer not we had a question if I could use a copper backer on this piece here i guess we couldn’t use the copper backer or any kind of backer to help back up the whole for this particular piece but you just have to remember that depending what you’re doing now for aluminum it’s obviously not going to stick and when you’re doing steel it’s not going to stick as much but the piece that the copper back and you may use may not be clean and when you go to start putting filler rod against it that’s melton molten it may actually have some impurities that will pop up through it the other thing I wanted to show is that you can always get a copper backer back there to kind of help you always have that helps i was trying to show this piece up above a little more difficult but in the real world i find like most times i like to use the copper back or I really need it I can’t use it but yes you could use a copper background would just make sure that it’s very clean before use it so I would almost hit out scotch-brite and everything and clean that up so you’re not dropping well down its touching it is then as impurities on it so i’ll keep you areally good it’s answered outside the valley and have a little more throw rods and I need in and go bigger than I need with their it got shut off so i’m going to show you before i flip it over and do the other side you can see again I let the the cleaning part of the AC side alternating current dance around actually went out further and you can see that little bit of a black halo there when i started quoting a clean around the center of where I was welding I saw a lot of contaminants and you know suit or something in there that was popping up so i let this Queen way outside of what I was welding because I didn’t want that impurities to pop and kind of find its way back into my well so went out much further than I needed and I got again I got that clearance effect with about AC balance control set a little more to the positive so I got a bigger Queen areas you can see that big halo around it we can see that just a little bit of black or gray which was contaminants that popped up i’m going to guess it’s from that grinder because i wasn’t a fresh flap discs i used so it’s probably I’ll tiny bit of contaminants in it from using it on steel or something else so that once filled this backside here not too much but they got those two little spots so I’m just start assuming here whatever we’re doing we want this this whole to completely disappear so I’m going to try and touch up those two little spots hit with the standard again see where we’re at and then hopefully the second pass we should have it so think they are getting here wire brush get into the crevasse it is alright storm I one-half piece of filler rod here i’m gonna try and get away with using just this so we’re monster hole so that the lands on Shay it the wedding queen again i’m going to try and fill this little tiny divot i have from when i when I’ll let off the pedal I got a little bit of a divot there that occurred after i left pedal a little quick alright so we’re going to start with the top piece going back and forth in that little area back in the center i’m barely on the pedal you don’t want to stop right now on the pedal I want to clean so i could see right in here is a bunch of that fruit pop up again from clean and way out into it and the Queen in that center section i think i’m gonna hit this park for this slowly getting on the pedal that one little dab of filler I’m gonna back off and let it go back to cleaning we’re not going to stop for this going to keep cleaning in here at this little halo gonna start outside of it a little dab and dad dad more back off or guess well filter little spots up there I’m gonna hit these real quick sander again and i’m just leaving the flat it and you know just real quickly show you guys but you were doing something that was need to be perfectly flat or machine you know of course you need to take a machine shop or do it yourself with a mill you could come over and mill this make it perfectly flap we know that were filled a hundred percent of the way through this hole so we can machine this drill it tap it do anything we want to it just like we would have originally before the hole was drilled so barely that’s the quick went over that of course without a straightedge hard to tell but you you want to have more material than you need so this is the top side here we can see it’s pretty much gone i could see a little tiny hello we’re a little section i repaired i can tell just by using the grinder there but i think i might the center might still be a little high so probably I would do it here is take a pic a a block blocks and it’s see where i’m at spray spray a dust coat or machinist eye on it and then sand it and i’ll tell you file it tell you where the high spots are this is our backside same thing a little just a little tiny hello there but I mean any what you’re doing you can go back and chase those little Mark’s you can sand them we could add more to the center all around and build it up and then sand it off same thing but that’s our piece we filled the hole and I don’t have to do that like a hundred more times if you’re doing a wheel or something like that but this is the process again if you were filling something that’s that’s much more thick would have to make a slug and drop it in and it’s and well if from both sides preferably but you have any other yeah we have three questions short uh first ones by fairly simple Dana on facebook like to know how high you are you holding the tungsten off the workpiece was Dana correct yes Dan out on facebook thanks for the question asked how I was holding the tungsten electrode off of the workpiece was working i’m keeping a pretty darn close what I like to teach when we’re doing a beginner class is the thickness of your filler rod that you’re using approximately it’s a good height so we’re using 332nd oubli 332nd so my electrode is about 3 30 $OPERAND seconds off of the workpiece approximately so that’s about how far we don’t want 16 I could have a sharpened and I lower amperage and I could be even closer to the piece we want to make sure that you have it i wouldn’t go much more than the height of what your filler rod is that’s a good question and Bob would like to know is what’s the technique if the metal was vertical as opposed to horizontal so Bobby asked what the technique would be if the metal was vertical instead of horizontal it’s basically the same the way I’m doing it one even if it was vertical what I would be doing is we’re feeling this whole here I’m I’m goose in the paddle or giving the pedal amperage when I want the filler rod in there so it’s not staying hot long enough for gravity to basically affect it where sometimes or when you’re welcome to stay with a MIG welder or stick it changes the technique because it going up and down but really all be doing is I would just speak goose in the pedal add some filler rod work my way around it until I get a nice i get just a keyhole almost and then I would same thing come right in from the center heat it up and just drop filler rod in in there till it fills up with the same basic process you just you’re going to be out of position a little more so you may have to turn your head a little bit but same thing and one other question from yannick who’s with us every week how would you solve high-frequency interference problems I feirense oh so yannick asked how would I solve hi sorry high-frequency interference high-frequency wish i ad can further explain and we’ll get back to ya because that that 1 i’m not sure what the interference he’s talking about what would be causing that you asking the interference when you’re welding with a high-frequency what would be well can you do to stop to stop that but I don’t know I’d like to know what’s causing interference if you’re right that’s what he can he can send us a message ya fue for if you can type it may be a little more detail and we can try to answer them yeah just give us a little more background what the problem is that you’re happy having I get better we can better answer it but off the top of my head I’m kind of a broad almost a broad but something i’m not sure what why is having that issue that would be causing that that is that interference so thats you got me stumped on that one but give us some more clarification either a message or drop it in the comments and weekend up we could try to answer the best we can afterwards so that’s all we got for questions thanks everybody for joining us as we do another wife text session make sure you follow us on Facebook and YouTube will be doing more of these lives we have another one are we working on the car this friday again we might be coming live friday with the door but tomorrow we’re going to do to show you a battery maintainer which is our daily deal ok so we’re we’re trying to do a live almost everyday now so tomorrow make sure you turn and we’re going to our daily deals shield about battery maintainer but no fridays we’re trying to get we’ve had some requests for you guys that like to see us actually working on a project field vehicle and you know the things that we we come up with certainly working on hopefully on need the door work on that project a little more than what you guys watching and give us some tips if you think we’re doing something wrong so thanks thanks everybody for watching we’re going to catch you next time thanks

3 thoughts on “TIG Welding Tips & Tricks – How to Fill Holes in Metal – Eastwood

  1. DON'T EVE USE A SANDER TO CLEAN ALUMINUM !!!! IT DOESN'T CLEAN IT ,,, IT PUSHES THE DIRT INTO THE ALUMINUM …..AND HE SHOULD KNOW THAT !!!!

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