Metal repair

[pmx_super]

I have a failed weld in the handle that releases the driver seat slider mechanism on my car. The car's only worth a few £k so I'm considering a DIY repair, and wanted to run my plan past a few practical minds. The picture shows the failed weld.

I'm thinking of a belt and braces approach where I:

1. Encase the whole joint in a 2 part epoxy like this, pushing some down into the hole from the back: https://www.jbweld.com/product/steelstik-epoxy-putty-stick

2. Drill through the joint (and the epoxy) along the red line, then put an M3 bolt through.

I'd appreciate recommendations for what product to use in pt1, if indeed there exists a product that's up to this job, plus any comments on my plan's likelihood of success or ideas to improve it.

I didn't post in the cars forum because this is an unorthodox repair.

Thanks

 

[Burnerman]

A nut and bolt will always be the best repair here, but 3mm is too small.
Can you up it to 5mm?
This could be MIG welded in 5 minutes if you can get the seat out.
John

 

[simplesteve]

+1 for the Mig Weld option. If you can get the seat out

 

[pmx_super]

3mm is too small. Can you up it to 5mm?

I could do 5mm, but I thought smaller would be better to avoid removing too much material, since the hollow circular rod wasn't designed to have force applied in that way. On the other hand I was unsure of using such a skinny bolt, which is why I mentioned it.

This could be MIG welded in 5 minutes if you can get the seat out.

That wouldn't be DIY for me. I thought of calling a welder, but even with the seat removed (which is easy) the weld is on top so there's no space to the underside of the seat, and dismantling the seat would be much harder.

Unfortunately that also means I'll have to drill into the circular rod first, instead of the flat surface, so any tips for hitting the centre of a round profile appreciated!

 

[Burnerman]

I still think this is a quite easy joint to weld - given access with the seat on a bench and the paint removed.....the weld build up would make things strong once again.
If you don't want to do this, I'd still go for a 5mm nut and bolt, which will tighten much more firmly than a 3mm.
John

 

[pmx_super]

If you don't want to do this, I'd still go for a 5mm nut and bolt, which will tighten much more firmly than a 3mm.
John

Job done and all sorted. A 5mm bolt was just the ticket. No need for any epoxy. Thanks for your input. £10 fix vs the £1,200 I was quoted by the dealer!