What is the secret for welding body panels? - FFCobra.com

TNCobra · 02-19-2009, 12:00 AM

I am starting to think about taking on the body of my project car. I have a small area of rust in the door that I cut out which measures 2x3 inch. I also want to patch up the antenna hole in the fender. I have a 110V, flux core Lincoln welder. I started practicing on the fender I swapped out, without too much success.

thank you in advance.

CobraDVM · 02-19-2009, 12:20 AM

I think if you haven't a lot of welding experience, MIG welding would be the way to go. But to answer your question, do lots of small spot welds to prevent over heating and deforming. Also make sure that the voltage is not too high otherwise you will burn through too easily.

Wayne Presley · 02-19-2009, 12:26 AM

Ditch the flux core and go mig, then do three more things. Practice followed by some practice and finishing with some practice.

mikeinatlanta · 02-19-2009, 12:28 AM

Yea, what he said. ^^^^ Ditch the flux core.

angelballer · 02-19-2009, 12:33 AM

I concur with the mig suggestion. Here are two links showing the restoration of a couple old Toyota's that show an extensive amount of bodywork. There is quite a bit of random stuff so I suggest skimming through it when you have some time.

Link 1
Link 2

Cobra Cory · 02-19-2009, 12:34 AM

Another link...

http://www.millerwelds.com/education...rticle150.html

lbperry · 02-19-2009, 12:36 AM

After you do the practices, in the welding class that I took we were taught that particularly on sheet metal you needed to 'stitch' weld it. Start with tack welds a couple of inches apart and then gradually fill in between the tack welds so that one area doesn't overheat and warp too much. You'll still have to work it with a body file, dolly, and filler to get it smooth.
Good Luck, even after I took the class, I got one of the good welders in class to do the touchy welding and I just did the body work.

ETriggs · 02-19-2009, 01:59 AM

What 110V Lincoln? I have the Pro Core 125 from Lowes, converted it over to MIG and it works great. After welding with MIG, I will NEVER go back to flux core. The conversion kit is K2526-1 and it will cost about $148 shipped to you.

USMC · 02-19-2009, 02:14 AM

MIG very low heat. If you are inexperienced, turn the car on its side so you weld in the downhand position.

Also, consider oxy/acetylene welding.

conmech · 02-19-2009, 02:21 AM

If I remember correctly, Flux core was designed to be used where ARGON bottles couldn't be taken (i.e., remote locations) and for hobbyists not having to have ARGON stored in the shop/garage. Personally, I would burn up some flux core wire to learn and move up to MIG later. Low heat, small spot welds are the way to go on thin sheet metal as mentioned. Less warpage of the material results in a better end product and less body filler to correct mistakes.

Warlock · 02-19-2009, 02:27 AM

Mig , ditch the flux, and lots of small tack welds...
Tack 2 to 3" apart and rotate tacking after each one of them to keep from hitting with to much heat and warping...
Patience, you'll be ok...

TXBLU · 02-19-2009, 02:39 AM

Quote:

Originally Posted by Wayne Presley

Ditch the flux core and go mig, then do three more things. Practice followed by some practice and finishing with some practice.

^^^^ Ding, ding, ding!!!! We have a winner.............!!!!

Eric

egum48 · 02-19-2009, 02:42 AM

http://www.azautobodysupply.com/lordfusor1.html

hind sight · 02-19-2009, 12:32 PM

Biggest problem when welding in patch panels is rusting later on.
Flux core mig just adds to this.
Gas mig works best along with weldable primer beforehand.
Couple spot welds then skip around till panel is completelly welded in.
Grap a few old fenders,doors,ect form a local body shop to practice on. They are the same thickness you'll be working with

USMC · 02-19-2009, 04:35 PM

Another key thing no one has mentioned that I learned the hard way, is don't be shy about how much of the old metal you cut away. I tended to not cut enough and then you are trying to weld to old metal that is as thick as a beer can. Be sure you cut all the way back until the metal is still the original thickness.

Also, are we talking butt weld or lap weld? A lot of the demos I have seen show the use of a tool to flange the old metal and then weld in the new panel with a lap weld. This weld is very easy to make. The problem with this is you potentially leave a place behind the panel for water to get in and get trapped.

Butt welds are much harder to make but eliminate the problem of a large space behind the weld.