Hi e-tek
I have read through your thread for the last three days from the beginning until the end. It's absolutely incredible how you handle different Projects at the same time and also the amount of work you are able to do during your free time considering that you are also a Family guy.

I'm really

Additional to that that you have a one man Show it even

me more.
There are a few points i noticed during the reading:
You wrote that you take a standard drill for spot drill welds. Why dont you use standard drills and grind them by yourself with the required center pin to get a flat top? I have done that different times and it works very well.
Why do you drill always for a spot weld and doesn't use a spot welding gun?
At the beginning I was asking myself why you doesn't take a joggling/ punching tool. But during your work you bought such an tool. I also own such an tool but for me the punched hole diameter of 5.5 mm was too short so I remanufactured the Punch and now I have a Diameter 7mm hole which is much more comfortable to weld and I believe also the welded spot got a better Penetration.
Your idea to use a flatened copper pipe to fix holes needs to be copied by me.
What I personally can not understand: I always see you guys with a full safety Equipment- but the protection at the angle grinder is missing (especially if you use the cutting discs). I'm not fanatic with safety rules, but please be carefull with you so that we are able to read many more of your stories.

I love your Hansen Socket trays- unfortunately they are not availble in Germany but the WWW makes it possible to buy these in the near future.
At #803 and #1073 you show us how to remove a broken stud. You also can try this: use a LARGE washer and weld it onto the broken stud, on top of the washer you can weld a large nut. Doing it this way it's much more accurat to weld through the thin washer. Sometimes you have to do this twice or three times until it works-but it works perfect because you can bring in much more heat into the System.
What I'm missing at your tools is a power file which is perfect for body work.
#1395 Incredible how a landlord can act in your country.

In Germany the tenants have more rights than the owners and to get them out normally ends in endless processes at the court.
Viele Grüße aus Deutschland and please keep us updated
Rainer