I will admit, I have not done a bunch of plug welding in my almost 9 years of being self employed. I had the opportunity to repair some trash, on some trash where when the trash was first built they didn't do plug welds. Had to locate the metal within the trash then cut out holes to do plug welds.
Get holes cut, cleaned and since I have never experienced "plug welds" my initial reaction was shock.
In my minds eye I saw a plug weld as a hole with the inner metal immediately behind the opening where you could weld inner base metal to exterior base metal. I wasn't expecting the inner metal anywhere from 3/4 to 1 inch away from the exterior base metal. I raised the question, WTF???? The short answer was, "That's how it's done" or "That's how it's always been done". My reply, "Hmmm, never did a test where I build out a weld thru open air for an inch before I can even touch what I am welding too". One and a half inch stringer bead, clean, run another, clean, run another, clean, talk about annoying!
Was like putting a 12" pipe standing up on the ground then putting a 10" pipe in the center with plastic spoons on the edge of the 12" to support the 10". Gave the whatever look, engineer approved and moved on.
So, my opinion was, Farm Code all the way but was wondering is this the norm? Since I have no flippin' clue what plug welds "shall" look like I figured I would come here and ask some of the more seasoned members.