Sheet metal plug tool

[Jaybr]

I'm sure you seasoned veterans figured this out a long time ago, but searching I didn't find much. I'm getting things finalized for paint and have some holes in the firewall I want to plug. Found a youtube video where the guy made a tool to punch out perfect round plugs so decided to give it a try. I used 2x2x4" blocks from Metal supermarket, paid $43 for 3 of them. Ordered cheap transfer punches from Amazon in 1/2", 3/4", and 1" and ground the nub off the tip and gave it a flat, somewhat sharp face (kept it cool while grinding). Drilled the blocks and cut a slot for the sheet metal. Slide the sheet metal into the slot past the hole and drop punch in a give it a couple solid swings of the hammer and out pops a nice round plug.
I also found you can order plugs from Eastwood after I started this little project, but what fun is that?
Before I found this I did make a couple manually using the belt sander by drilling the sheetmetal and welding a small nail in the center and turning it on the sander with a drill, but that was a PITA and once this tool is made it takes 30 seconds or less to make a plug.

 

[Speedrdr]

How close to the top of the “die” is the slot cut? Maybe show me a pic from the side de and end views? I can’t visualize how it’s cutting the perfect little discs without bending them in the middle. there are holes that I would fill also.

Randy

 

[Jaybr]

I cut the slot in the middle but not sure how much it matters. I also think I went too big on the blocks I started with, they work great but harder to drill than necessary.

Here’s the video where I got the idea, he walks you through making them.

Sent from my iPhone using Tapatalk

 

[Speedrdr]

Okay. It’s a solid block that is through-drilled with a slot and NOT a section of square tubing as I thought. Makes sense now. Thanks for the clarification.

Randy