I ordered some 1.2mm stainless steel sheet for my bathroom refit and due to a mis-communication it came with predrilled holes. As I did not have time to order new, to fill them I decided to TIG weld them.
The setup was a 1mm tungsten, 45A, pulsed at approx. 3hz with some heavy steel plate as a backing, about 30mm in total, I just used the earth clamp to hold this against the back. Rather than grinding the tungsten, I just snipped the end with a pair of pliers, this seemed to work well and was a lot faster than grinding.
As this was an unexpected job for filler wire I used a reel of 0.8mm stainless wire I got from the local Halfords. I don’t recommend the reeled wire as it’s a bit springy and you really need to bend it straight before use.
I just worked my way around the hole adding a small amount of filler rod. Once the hole was filled I turned the sheet over and just used to torch to work the exiting metal to get a flatter result.
I also had trouble with my mask, it was either too dark or too bright. It was a bit of a rushed job so I did not have chance to experiment. Chad Mustard from Condor Industries suggested “turn the sensitivity down and shade 10 as a starter then just tweek a bit”
Finally, I ground the welds down using a flap disk. It made a nice pattern so I ground the rest of the sheet to match.
Obviously the next step is to put the shower tidy back on the wall.