On this roll bar they just tightened the bolts down and that force a kinda of squared out spot for the roll bar on sheet metal of the wheel well. When I first came across the issue of repairing the holes, I planned to skip it and use some larger outside square patches then double up on some foam padding for the wheel well covers and just try to hide the damage under the upholstery work. Now that I have gained some experience, I decided to smooth plug the holes and get the car back to original with the wheel-covers glued right to the wheel well.
Pounding out the metal was not too difficult after gaining some experience, but welding a 7/16 holes has been a challenge. I tried the washer idea, but just could not get it going. Perhaps I had a poor ground. I did grind off the finish? Anyways I cut some plugs with snips then ground them true and welded them in with the MIG. This time I use some copper pennies taped on both sides in place to bridge the hole plus get a better ground, and got it.
Back in the 70ites I worked for this sheet metal shop on gutters and downspouts that we soldered at the ends, corners, and outlets. We put on miles of that stuff and that experience comes in handy. In the future, I might try using more soldering because the MIG is difficult in those little areas.