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Best Drill Bit Size For Plug Welding


Best Answer minidaves , 26 September 2016 - 06:32 AM

6 or 8 mm depends 

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#1 GT Jimmy

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Posted 25 September 2016 - 08:34 AM

Probably been asked on here many a time but what's the best size bit for plug weld holes? Was thinking 6 or 7mm. Thanks

#2 Marco1972

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Posted 25 September 2016 - 08:52 AM

I use 6 MM on 99% of my plug welds
5mm occasionally

Edited by Marco1972, 25 September 2016 - 08:52 AM.


#3 alex-95

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Posted 25 September 2016 - 08:57 AM

6MM for me to



#4 GT Jimmy

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Posted 25 September 2016 - 09:02 AM

Thanks. Off to screwfix now

#5 Ben_O

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Posted 25 September 2016 - 10:54 AM

Go 8mm in more structural areas although i expect you will read this after you return from Screwfix  >_<



#6 GT Jimmy

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Posted 25 September 2016 - 11:44 AM

Go 8mm in more structural areas although i expect you will read this after you return from Screwfix  >_<

Indeed I did haha

#7 sonikk4

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Posted 25 September 2016 - 03:24 PM

1/4" is perfect for most heavy duty applications. BUT remember the size of the flange will dictate what size drill bit to use.

The smallest I will go down to is 3/16ths. 5/32nd is too small. The hole will fill first without making a decent puddle of weld to the underlying panel rendering it weak.

8mm Ben is a monster but I can see its application in a couple of areas.

#8 Ben_O

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Posted 25 September 2016 - 03:42 PM

8mm Ben is a monster but I can see its application in a couple of areas.

A majority of plug welds i would do using a 6mm hole but i do like to go a bit overkill in some areas like heel and toe boards. the other option using 6mm holes is to space them quite closely to give more strength.



#9 GT Jimmy

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Posted 25 September 2016 - 09:40 PM

8mm Ben is a monster but I can see its application in a couple of areas.

A majority of plug welds i would do using a 6mm hole but i do like to go a bit overkill in some areas like heel and toe boards. the other option using 6mm holes is to space them quite closely to give more strength.
On the front toe boards I drilled the spot welds out using an 8mm spot weld drill, just thought it would get the welds easier. Guess I just got lucky haha

#10 minidaves

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Posted 26 September 2016 - 06:32 AM   Best Answer

6 or 8 mm depends 






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