I have an 87 Volvo 240 and I want to remove some of the ugly exterior trim. This would leave approx 40 x 4mm holes in the various body panels. Just wanted to get your opinions on the best way to achieve this. I have both mig and tig available to weld them up but I'm significantly more confident with MIG.

Thoughts??

Cheers

Liam Mc

mig is ideal. I am always filling holes with mine, often where a few seconds before there was what looked like good steel

If you're more comfortable with MIG then I'd go with MIG.

From experience welding thin sheet (tin top) takes a bit of getting right to avoid blowing holes in it. There are some good videos on YouTube talking you through the process.

If you can get it behind the panel then a dissimilar flat heat sink will help behind the holes.

Some recommend blowing the weld area with compressed air (if you have it) between each weld to help minimise heat distortion.

Performing a countersunk lap seam may help reduce blow through...