I've drilled 1/4 holes into the panel, then cut a strip of sheet metal about 1 1/4 wide, spray it with weld thru primer, use vice grip clamps to hold the strip onto the back side of the panel and leave about 3/4 in. to weld the new panel onto (in other words lining it up from the back side) then weld in the 1/4 holes. Now its flanged. This is how I do all my patch panels,kind of a pain in the *** but its easier to weld the new panel to ( thicker metal). I've even used self tapping screws to hold down the panel to the flange. If you mig weld enough you have to be able to weld in burn thru holes, I've pretty go at that now........ I only butt weld when I really need to.
Last edited by dogwater; 04-30-2013 at 08:13 AM.
Reason: more info