Welding Tips

[JoDan]

I'm planning on fixing the rust on my car sometime in the near future, but theres some spots that I'm going to have to cut out and patch up... so does anyone have some tips on like what kind of metal to use and any tricks I can use to get this job done and looking nice?

[Ogrestiva]

What kind of wielder are you going to use? My friend tried to wield using a mig wielder and the festiva metal melted before he could stick it to itself, it just disintegrated. He finally just decided to use a bolt and melted it to the two pieces and used it as solder.

[JoDan]

Yea, I'm going to use a mig welder with flux core wire

[Ogrestiva]

Yeah, that's what he used. he couldn't set the voltage any lower, so he tried to extend the wire faster, but to no avail.

[JoDan]

Idk... once I find out what metal gauge I should use I'll do some playing with the machine and hopefully find something that will work out nicely... if i had gas I wouldn't be asking for help lol

[gorgonheimer]

a small 110 unit mig should be ok. the flux core wire doesnt make for a pretty weld though. i would recomend "stitching" the piece in. use small tack welds at the corners and continue around in a circle so the metal has time to cool in between. this will help keep it from warping with the heat

[jglutz]

Arc (stick) welding cheap investment and take alot of skill for thin sheet metal
TIG Welding...big $$
Gas Welding....oxy-acetylene...Very handy to have around but difficult for thin metal on the festy.
MIG Welding...The best bet....medium $$

Metal to use....any medium carbon steel...CRS or HRS...of the same or aproximate thickness...makes the heat seting easier.

[Levitan]

Find a Festy hood that is not roadworthy and use it for your metal. I probably have an extra hood if you want it.

[CharlieZ]

I scrounge old file cabinets. The sides and back give you a lot of flat metal. The cheaper discount store cabinets are "better." (?) The metal is thinner. Works for me.

[worfdog]

I read somewhere guys were using old refrigerators and washing machines and the like for metal to make repairs.

[JoDan]

Well I bet I can find some old filing cabinets for sure, and using a hood is an awesome idea, but a drive to des moines and back will be a drag.. plus my festy shakes on the interstate

[JoDan]

Ok, so I got some old filing cabinets, so when I tack on the metal to the car... do I just grind down the welds and then put some filler in the rest and thats it?

[Levitan]

I would cut some small strips or squares of the file cabinets and practice welding them together. Stitch weld is what I think you want to do...least I think that's what they call it. Zap...move an inch over....zap.....move an inch over.....zap. Go back to the beginning and connect the zaps with zaps. You have to let the metal cool for a second or two between each zap or you will blow through the metal. Eventually you'll have a bunch of zaps strung together to make a complete weld.

Sand or file or grind the areas that you are welding. You want to be able to weld on "clean" metal. After welding, grind the welds down flat. Personally, since the metal is so thin, I'd tap the seam in 1/16th of an inch so I didn't have to worry about grinding the welds all the way down, hence accidently grinding through the metal. I'd wire wheel and/or sand any smoke contamination off. I'd wipe it with some metal prep. Bondo it in, cheese grate it before the Bondo dried completely. Sand it down......I'd find a basic body work site or book to educate me on the different grits of sandpaper and the order they should be used. I'd get the prep work done to perfection. I'd spray any bare metal with self etching primer. Then spray with 6 or 8 coats of regular primer. Spray a guide coat of a different color primer. Wet sand the guide coat off....etc. etc... etc. But that's just me.

I'm not telling you what to do, I'm just saying what I'd do. I'd hate to tell you something wrong.

[JoDan]

Don't worry about giving me wrong info. Its always helpful and appreciated to get some ideas on how to do it so it will turn out nice. Once again I appreciate the info... thats why I love this site.

[rallyon]

Make sure to use the thinnest MIG wire and tip available (.023, ER70) USE GAS IF YOU CAN, ARGON or 75/25 is coolest. Run about 1/4' stickout of wire from tip and keep wire 90 deg to seam. Make sure your welder is good working order! smooth feeding liner and clean tip. It all matters when welding thin stuff.

If the patch is small you can use a slightly heavier gauge steel then the body (18G) and focus some of the heat on the thicker stuff.

also same as others said: tac about 1/2 to and inch apart and let cool for a sec then go back around. it just takes time.

ALSO, make sure patch butts TIGHTLY to surrounding metal, no gaps, they will make it easier to burn through.

shaving antenna hole the other day:



Good luck, have fun.