I am in the process of rust repair on a Triumph GT6 and at the point of repairing things like the inner wheel well and some inner rocker pieces. These are all things that will be hidden and I can practice my welding.

My biggest issue (other than blow thru) is cutting patch panels. I will typically cut a patch piece out of some sheet metal in the general shape I need then hold it to the body and use a sharpie to outline.

Using a 3in cutoff wheel I will cut inside the sharpie and then slowly trim the patch piece to fit. I will trim using either sheet metal shears or usually taking my grinder with a 4.5 inch 80 grit sanding pad and sand the patch piece down.

This will get me close but invariably i will end up with an area that has a gap. This is wear I run into trouble with blowing through the sheet metal.

Any other suggestions on a better process?

make a template, grab a piece of card board or poster board and cut that to the shape you need , that way you can see how its going to fit before you start welding, then transfer it to your patch panel

In addition to that I like to use layout fluid (dykem) where ever your cut line will be. Then use a metal scribe to mark the cut line. and that will give you a very accurate cut line. A body saw and metal snips will make an accurate cut.

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Nice tool but don't get the one from Harbor Freight.
I purchased it and after trying to use it one time threw it away. JUNK

i use a diegrinder with a thin cutoff wheel, nice sharp and accurate cut
also, ive found it harder to make small patch panels, anything that has shape to it and is less than half the size of your hand, is hard to make.
the biggest tip, dont cut the panel until after you have made the new piece!!
krem

'68 Coronet R/T wrote:Nice tool but don't get the one from Harbor Freight.
I purchased it and after trying to use it one time threw it away. JUNK

I got two From HF when I bought mine because I knew the first one would fall apart ASAP and sure enough the plastic guard fell off of the one in no time flat.

I would like to find a smaller thinner model that was built better and was stronger when I say stronger I mean the Motor stroke strength.
The one on the Snap on Truck is just as big and 15 X the price

I like how accurate and thin the cut is!

I have also looked into Chevmans Idea of using the Punch Slugs from a Metal Hand punch to fill the holes made by Spot weld cutters and Drill bits.
Hi Quality Hole punches are the same thing if you buy the cheap China made ones you know its gonna break OR the Punches and Dies will were out super fast so rather than chase my Tail I bit the Bullet and Got a USA made Roper Whitney # 10 although The 16 looks like a Better machine for what I think I want or need I couldn't beat the Price I paid for the one I got on Ebay cant wait till it gets here to try the idea out.

Thanks Chevman for always showing & Sharing