Plug welds...

[Ghost]

Ok, so when welding plating to the unibody, frame stifiners, body armor, steering box bracing, etc. what size holes do you put in for the plug welds? I have used .50 in the past but it seems too small some times. I was thinking more on the lines of .75 but have also considered 1" too.

 

[IntrepidXJ]

i've always used .5 myself

 

[DaffyXJ]

I used 5/8ths on the frame plates. 1/2 on the steering box brace. depends on the spacing between the rosettes.

 

[Ghost]

I used 5/8ths on the frame plates. 1/2 on the steering box brace. depends on the spacing between the rosettes.

How much spacing did you use between them on the steering box brace?

 

[Goatman]

I think it has most to do with you being comfortable that you're getting good weld penetration in the hole. I think 1/2" is fine.

 

[RCP Phx]

As long as your not compromising the strength of the re-inforcement, larger is bettter(more surface area),I'll use this as a possible example of a weld on bumper plate!Easier to do a "controlled" weld also.

 

[Ghost]

As long as your not compromising the strength of the re-inforcement, larger is bettter(more surface area),I'll use this as a possible example of a weld on bumper plate!Easier to do a "controlled" weld also.

What size are those holes? MAN, they are huge. Any shots of them welded up?

 

[RCP Phx]

What size are those holes? MAN, they are huge. Any shots of them welded up?

Anywhere from 3/4" to 1-1/2",but these are my "bolt-on" bumper brackets!

 

[Ghost]

Anywhere from 3/4" to 1-1/2",but these are my "bolt-on" bumper brackets!

Oh so those are for weight saving?

 

[vetteboy]

It also depends on the thickness of the material you're plating with.

The holes in the frame plates I got from TMR are pretty large, but these get rosette welded, which is different than a plug...

 

[Ghost]

It also depends on the thickness of the material you're plating with.

The holes in the frame plates I got from TMR are pretty large, but these get rosette welded, which is different than a plug...

This is .25 I'm going to weld on the inside and botom and outside of frame rail where the steering box mounts.

The holes in the frame plates I got from TMR are pretty large, but these get rosette welded, which is different than a plug...

Hmm, I thougth they were the same. What is the difference?

 

[Begster]

Hmm, I thougth they were the same. What is the difference?

I was under this impression as well. I just did some searching, and this website said under Rosette weld to see plug weld.
http://www.motorera.com/dictionary/RO.HTM

 

[vetteboy]

I think you may be right - what I was thinking of was the difference between filling the hole completely (as you'd do with a 1/2" hole) vs. welding the perimeter of the hole (as on the frame plates I posted).

 

[Starboard M]

1/2'' holes.

 

[ZacSquatch]

we used .5 on mine last month, they weren't too bad. Sucked with flux core though.

 

[XJ_ranger]

given that the majority of the XJ body is spot welded together...

I think 3/8" is more than adiquite... and just about the right size for a mig welder...

good reading in this thread - particularly by Captain Ron -
http://www.naxja.org/forum/showthread.php?t=932148