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plug an exhaust hole

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Wes in Ohio

05-18-2006 20:07:36




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I purchased a new exhaust manifold and noticed right away the pipe runs up the middle of the manifold, my old one ran up the front of the manifold(was really a downward exhaust turned upside down) now I have a big hole to fill. My idea is to weld a piece of sheet metal on the backside of the hood, then fill remaining void with bondo and sand flush, never done body work just my idea, anybody got any idea on the best way to fill this hole
Wes

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RobertTX

05-19-2006 08:20:10




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 Re: plug an exhaust hole in reply to Wes in Ohio, 05-18-2006 20:07:36  
If you can TIG weld, it will work best to cut a patch to fit the hole and weld it in flush. Use the bondo to fill grinder marks and level the surface and you will have avery nice repair.



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davpal

05-18-2006 22:40:09




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 Re: plug an exhaust hole in reply to Wes in Ohio, 05-18-2006 20:07:36  
If you have never done body work I would not weld the hood. It will warp the living daylights out of it. If you do be careful to keep the surrounding area very cool and do tiny spots at a time. You can make a huge mess from a small repair. If you can't see the bottom side I would actually patch the hole shut with a piece of fiberglass repair patch and some resin. It will dry rock hard and be very strong. Then you can just apply bondo to the top and finish it smooth. Much easier than if you warp the piece trying to weld it. Good luck.

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souNdguy

05-18-2006 21:41:43




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 Re: plug an exhaust hole in reply to Wes in Ohio, 05-18-2006 20:07:36  
Yep.. you can stitch weld it.. or if you are not great welding thin stuff, braze or solder the patch in place. heck.. I've used sheet metal flashing and jb weld to apply a patch to the backside of metal.. File or grind any 'proud' portion of the hole down even with sourounding metal.. or even undercut it a little to help with smoothing..let it cure, then use a skim coat of bondo to bring the grooves into contour, and you couldn't tell there was a hole there once painted.

Soundguy

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Wes in Ohio

05-19-2006 04:56:03




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 Re: plug an exhaust hole in reply to souNdguy, 05-18-2006 21:41:43  
I planned tig welding it in I'm fairly good with a welder, really wanted to make sure bondo was ok since I never have used it, I'll give it a shot and let you know how it goes Thanks for your input
Wes



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souNdguy

05-19-2006 08:58:19




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 Re: plug an exhaust hole in reply to Wes in Ohio, 05-19-2006 04:56:03  
Incedentally.. in small areas, i've mixed up that 4 minute jb weld, and slathered iton instead of bondo. for thin skim coats it sticks better.. doesn;'t lift or chip, will take up a much smoother finish than bondo will.. so takes primer much better.

Soundguy



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CNKS

05-19-2006 11:19:41




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 Re: plug an exhaust hole in reply to souNdguy, 05-19-2006 08:58:19  
4 minute JB weld? Is that the stuff called qwik set or something like that? If so it is hard for me to sand, compared to body filler. I do use it in places where I think bondo is not appropriate, but I use a skim coat of body filler, or perhaps 2-part glazing putty over it, then sand smooth. Usually invisible if I do it right.



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EX-pro

05-20-2006 08:22:26




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 Re: plug an exhaust hole in reply to CNKS, 05-19-2006 11:19:41  
Duraglass is the one I use. It is like "Bondo" with ground fiberglass in it. It keeps enough flex to not crack if you are on a spot that may move some.



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souNdguy

05-20-2006 08:01:16




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 Re: plug an exhaust hole in reply to CNKS, 05-19-2006 11:19:41  
I think it is called jb qwick. I've found that actually letting it set up longer.. like an hour or more makes it sand pretty good.. Like you though.. I only use it in 'problem' areas where I don't feel a thin coat or blob of bondo will hold.

Soundguy



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B-maniac

05-19-2006 19:43:41




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 Re: plug an exhaust hole in reply to CNKS, 05-19-2006 11:19:41  
It is actually called 4 minute JB Weld and it is just the ticket for gluing a patch on the underside of anything. Never thought I'd say it but welding is becomming "old school" in quite a few applications now-a-days.



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