Buying Guide

How To Weld Auto Body Sheet Metal

Have you tried melting thin metal sheets before? If not, I invite you to try welding auto body sheet metal, a thin metal often used in commercial vehicles such as automobiles and motorbikes. Auto body sheet metal is easy to buy – but difficult to weld! Even the most experienced welders have trouble regularly getting it right.

Creating perfect joints can be tough, as excess heat causes warping or buckling. It’s also important to know that thin metals are easily dented when being worked on; so take extra care not to press too hard while cutting into the material. Welding auto body sheet metal requires a delicate touch – which sounds like something only a true expert could do! Still interested?

Welding thick metal sheets are pretty easy, but did you know that there’s a lot of practice involved when it comes to welding thin sheets? Welding thin metal sheets are sometimes so tricky that even the most experienced worker may accidentally ruin the joint by having not welded it properly.

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Auto Body Sheet Metal Welding With Different Welders

Are you planning to weld an auto body with MIG or tig? It is important that you know what to look out for when welding thinner metals so as not to create unsightly situations or unwanted outcomes. Here are some tips and tricks that might be helpful in this matter of welding thin metal.

Doing It With a MIG Welder

When welding sheet metal, it is best to select the correct wire diameter based on the thickness of the material. If you use a thinner base metal, you will have more flexibility when working with materials, be less likely to cause damage to your work, and still produce a quality repair.

How to Weld Auto Body Sheet Metal With a TIG Welder

To weld auto body sheet metal, created, thoriated, or electrode tungsten is typically used; however, to avoid overheating issues 1/16-inch and softer like silicon bronze is recommended to use as a filler material. If you’re comfortable enough with the process, it’s better to use pointed electrodes for more control over your welding.

As a car bodyworker, you can use either created tungsten electrodes or thoriated tungsten electrodes with 1/8-inch diameter when welding. As an alternative to a 1/8-inch electrode, you may want to try a smaller one. Although smaller in size, it will give you more control over the situation and will look nicer when finished too. A 1/16- inch tungsten tip is the best compromise between control over quantity when welding the sheet metal. An experienced welder can get good results even with a magnetic set up on mild steel with no backing material as long as he or she keeps heat input low and smooths out the joint by moving along it during weld folding.

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Essential Tips on How to Weld Auto Body Sheet Metal

  • Take it slow when welding auto body sheet metal.
  • Start with the lowest power setting.
  • Clean up the metal before you start
  • Measure before you start

Safety Tips of How To Weld Auto Body Sheet Metal


First off, it’s important to never go too fast when it comes to welding a car body. To achieve successful results, one should always clean the metals before beginning their project so as to avoid the accumulation of grease and other grime from contaminating the welds.

When it comes down to choosing between manual welding methods and auto-welding equipment, the choice is up to personal taste and what results you want for your project. However, proper safety measures should always be taken no matter which option you’re going with!

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