Stitching In Panels Question

I’m working on patching bad segments I cut out of my jeep and hope you guys can help. I have basic home tools - no metal brake, no cnc. But I do have lost of hammers, a mig welder, and a torch!

First question: how to fill a crappy circular repair like this.
My initial plan was to cut it out with a bimetal hole saw and then cut out a plug with the same hole saw, but there were two problems. First, although the hole saw thickness is 1/16, it’s kerf is 1/8, which is too big a gap around the repair. The second problem is that it takes a long time to get through the patch metal. I bought 14ga thinking it would be more durable than 16 or 18, but I am getting bit by its poor workability.


Is there a better way to patch these holes? Carbide bits, thinner sheet metal, buy the next side bigger bit for the donor site?

Second question is about stitching in bigger pieces of panels. I think I know the right answer. I initially cut out the problem metal and left the “flange” in the panel, planning to stitch the edge of the patch to the flange.
I think I am going to be better off cutting out the flange and forming it into the sheet metal I am stitching in. Is that the correct move?

 

yes on the flange as far as the round hole....cut it square easier to make a square patch

 

For the wider gaps, hold a piece of brass or aluminum behind the crack. Helps to prevent blowing the gap wilder. Ron

 

I tried a hole saw once... next time i'll try a Jig saw and circle guide.

 

For the round patch just cut out it genrally from the sheet and trim it up to fit using whatever you have. grinder or tin snips. Probably too hard to cut 14 with hand shears though. You dont want to be filling an 1/8" gap it puts too much heat in and too much grinding itll be messier than it was before.

 

I use a throat-less shear to cut circle patches. I can get very close to the size, then a little grinding with a flap wheel to get the gap perfect.

 

Considered a pair of flanging pliers? Makes flush fitting simple. And then perhaps brazing the patches?

I made a set of flangers once just by modifying a pair of vise-grips. Copied Eastwood's design.

 

I read that thread before I started patching the small holes! Thanks. I also purchased some premade sheet metal plugs but they didn’t come big enough to span two holes I need to cut out. I’m working on rear fenders now and will post pics on my build thread when done. Thanks, everybody.

 

I stumbled across this video a while back and tried the technique last year fixing up the CJ body. It works very well if you are careful with the cuts. This guy has a lot of other cool videos. He does nice sheet metal work with limited specialty tools.

 

Dude tack welds with regular safety glasses!

 

I saw one guy weld using his cell phone using the photo app. Lol