Project "Cheapskate"
About 20,000 bikes vs 100,000 or so...a little more my speed, but still a great time!
Probably do the same this year.
(please excuse the interruption. Now back to work everyone.)
I'd try to sneak out from the wife and kids, and buy you a burger and a beer.
First take some scrap paint prep 16 Ga metal, put behind the holes to fill, and draw an outline with a felt pen. Then cut out your plugs file or grind to fit the holes.


Then I use masking tape to hold them from the back while I carefully spot weld them in place using a mig welder on low heat.

Forgot to take pictures of the spot welded plugs, sorry. Basically I just hop from plug to plug and make a little weld, moving around keeps them from getting to hot and warping the metal. I also filled the two little hole by just welding them shut, no plug.
Now grind the plugs smooth and put a skim coat of filler on. Then to the booth for primer.


And yes I filled over the stud instead of cutting it out and welding in another plug.
The primer is drying while I wait for the tornado warning to expire, then hopefully back to the shop, sand the primer, spray sealer, and paint.
30 years later I have a 30 X 50 detached pole barn that I built a paint booth inside. It is 15 foot wide and 24 feet long. I found an DeVilibis exhaust fan on craigslist for $200. There are six eight foot florescent fixtures on the ceiling from an old warehouse. Then there are six 4' four light fixtures in the side walls.




Most of the time I have a 73' Dodge Challenger project parked in it. I needed a change of pace and decided to do a bagger over the winter (now spring).....

I don't do this for a living, Just a hobby, and a place to escape to. Turn on the stereo, light up a stogie and play.
Last edited by Batman7349; Apr 15, 2012 at 07:13 AM.
The Best of Harley-Davidson for Lifelong Riders
Ride with pride and safety in mind on that beauty.
Ride with pride and safety in mind on that beauty.
In the booth now, sealer is on the rear fender and the bag lids. The final items to paint. Then on with the assembly. Pictures later after the clear is on.





