Brazing Holes In Sheet Metal

A convenient method of preplacing filler metal is by using a brazing sheet an aluminum alloy base metal coated on one or both sides.

Brazing holes in sheet metal.

For thicker sheet metal an old copper penny might be a quick source of material. Using lineman s pliers the plug is cut to shape slowly snipping into a circle. If you are going to weld on thin sheet metal such as car body parts then you re going to have holes to weld from time to time. Position the metal as desired.

A filler for the holes is needed i used some soft copper from a pipe hanging fixture hammered flat it was a perfect thickness for this application. Brazing is a quick and inexpensive alternative to welding. Holes in thin metal can be filled with plugs. Heat treatable or core alloys composed mainly of manganese or magnesium are also used.

Then clean the surfaces using soapy water or a. Steps use the wire brush or emery cloth to scuff the surface of the metal. Brazing is distinguished from welding because it uses an intermediary material usually a copper zinc alloy to join the two metal pieces rather than melting the pieces. If the hole needs to contain a liquid a rubber washer can go on the sheet metal screw to render it water tight.

Brazed metal can also be stronger then welds. Brazing is a technique for joining pieces of metal together by filling the join between the two metal pieces with a molten intermediary metal. Brazing is also much easier then welding it s a lot like using a glue gun. And for personal projects and small production runs brazing is much more cost effective.

This may be due to burning through the thin sheet metal welding molding holes fabrication or other reasons needed. In most cases an overlapped joint will be stronger and braze together easier than a. Heat the joint where the two pieces of metal will meet. The kind of plug to use depends on how the thin metal is being used.

The equipment in this project can be bought for as little as 30 dollars.