Just do a search ( as I just did moments ago) with “how to duplicate the look of spot welds” and a number of different techniques pop up. These are generally multi-step procedures involving a spot welder, drilling, filling, grinding and punching. Many different techniques…
Best to get some sheet metal of appropriate gauge and practice until you get the look you want. May be helpful to have detailed photos AND measurements as a guide.
Hi Michael, long time buddy...
Yes, I started with a search and this is how I came up with info on the different techniques (that I mentioned) to duplicate the spot welds. Also posted this thread after I've spoken to Wallace about his experience in welding.
I am in the middle of another restoration, on my '61 Alfa Romeo Giulietta and just last week had to replace an inside panel section that had been spot welded in place. Since I don't have a spot welder, I plug welded it. This means: drilling not-too-large holes in the new panel, spaced regularly apart, then welding the hole full of new steel/weld and so weld the new to the old underneath. Yes it creates a small raised area (depending on how much material you deposit) but that can be ground out to resemble the 'dimple' that a spot weld creates. That would be a lot of extra work though (precise grinding) so it would be more efficient and better to just get a spot welder, they are not that expensive. Now it may not always be possible to use the spot welder depending on the sequence with which the original panels were welded in.
In the photo you can see the first (top) two of the plug welds I did on the Alfa:
Yes, I have seen this technique, quite risky and time consuming. The margin of error is really low with it. Prefer to source a better mean of spot welding.
I thought to ask the good folks on this group about their experience with Lanco (those who used it). I did PM a member who did but got no reply as of now.
What caught my attention about this welding device is that the two jaws don't have to be directly opposite each other. Just need to be in the same vicinity on opposite sides. With in reason, you could spot weld most of the repair panels together. I have never used the Lanco welder, so have no idea how effective it is. Just looks promising given the price.
Wallace, it is a fantastic machine and again if all fails, I will simply purchase it and do some R&D on the tips until I get the spot welds perfectly.
You do know that you can also use one tip only to focus on each spot weld?
Another option I thought of is to reach out to the manufacturer and see if he can modify the tips for the perfect spot weld. Guess need to send him a sample to duplicate though. (Hope I am making sense here lol).
