Puddle Weld | EASY - 2025 |

Those little circles of steel aren't spots; they are puddles of strength holding your world together. Do you have a horror story of a plug weld that failed, or a trick for getting them perfect every time? Let us know in the comments below!

Instead of welding the outside edges of the overlap (which can look messy and trap moisture), you drill or punch a hole in the top sheet. You then direct your welding arc into that hole, creating a "puddle" of molten metal that bonds the top sheet to the underlying parent metal. When you finish, the hole is filled flush with weld metal. puddle weld

If you’ve ever wondered how the floor pans are attached to the frame of your car, or how a sheet metal bracket is secured to a hollow tube, you’ve likely seen a puddle weld. Here is your complete guide to what it is, why it’s used, and how to do it right. A puddle weld is a method of joining two pieces of metal—usually where one piece overlaps the other—by melting through a hole in the top layer to fuse it to the bottom layer. Those little circles of steel aren't spots; they