Plug weld drill bit.

MP&C

MP&C

Member
I normally use epoxy on all panels before putting two panels together for a plug weld.
This video shows Flattening and backfacing a drill bit to clean paint off the adjacent panel in a plug weld hole...





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60 grit 3M Cubitron, drill bits from McMaster Carr. I had someone on my YouTube video comment that he would use a leather glove, so I guess there’s that option. (Don’t know why he wouldn’t use a pair of gloves) In a case like this I prefer the dexterity that a bare hand offers so I can be more precise with my results, but at the end of the day you have to be comfortable with the process. For cleaning paint for plug welds, I find this a better option over using a sanding disc. Leaves more primer there for rust protection.
 
I have drill bit dispenser cabinets, so about a dozen or better of each size in fractions, letter, and number. So if I need a smaller plug weld to accommodate a narrow flange, or other sizes as needed, I simply drill the size plug weld hole desired and make a cleanout bit to fit that size as shown in the video. Since they are flat, It’s only cleaning paint from the adjacent panel, so they just about last forever. As to the 135* drill bit, IMO a drill bit of whatever taper you’d like is going to cut into the next layer, no if’s ands or buts. Since I run my welder on the hot side, that isn’t an option for me as it would blow through. End mills are about 3 to 5 times the cost of drill bits, unless you have a good source.. But use whatever means works for you. I was just showing this as an option to clean for plug welds while leaving as much rust protection as possible.
 
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