Welding sheet metal

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Spook50

Spook50

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The tune up is almost done on the Duster, and I'm going to work on stripping out the interior (with the exception of what I need to drive the car) and then installing an A833OD 4-spd. To do the conversion, I've got to cut a section of the tranny hump away and install a new hump (fortunately I found stamped steel reproduction humps). I've never welded sheet metal before though. Would I be better off having someone else weld it in, or is it something a novice can pick up fairly easily? I'd love to say I did it all myself, but I'm not above swallowing my pride if that's what it takes to get a better end result.
 
swallow your pride
 
you've never welded sheet metal before, or you've never welded before at all?
 
Oh come on you guys... We are supposed to give support and encouragement for this type of thing, right? You will be able to buy some new toys (welder) and gain valuable experience in a new endevor. Welding sheet metal in a floor is no where near as hard as doing it in a body pannel. Trace the new pan size, cut out the old sheet and lay in the new sheet and tack it in all around and then connect the dots. .025 wire and a bit of trial and error on a test piece and away you go... Give it a shot Spook, welding is a hoot.
 
photogod said:
Oh come on you guys... We are supposed to give support and encouragement for this type of thing, right? You will be able to buy some new toys (welder) and gain valuable experience in a new endevor. Welding sheet metal in a floor is no where near as hard as doing it in a body pannel. Trace the new pan size, cut out the old sheet and lay in the new sheet and tack it in all around and then connect the dots. .025 wire and a bit of trial and error on a test piece and away you go... Give it a shot Spook, welding is a hoot.
Click to expand...

This is his pride and joy that he has been posting about for two months. Not a rusted out 40 that he cannot hurt the apperance of. :flipoff2:
 
I realize that but where is the uplifting support needed in a time of self doubt? ;p I welded a topper for my trailer and it was the first time I ever welded sheet stock and I did a few test welds on extra stock and away I went. Near perfect welds and zero puckers.... And if I can do it a monkey can do it. No offense Spook. ;)
 
photogod said:
I realize that but where is the uplifting support needed in a time of self doubt? ;p I welded a topper for my trailer and it was the first time I ever welded sheet stock and I did a few test welds on extra stock and away I went. Near perfect welds and zero puckers.... And if I can do it a monkey can do it. No offense Spook. ;)
Click to expand...

Good point.

He will not get good at it unless he tries.
 
photogod said:
Oh come on you guys... We are supposed to give support and encouragement for this type of thing, right? You will be able to buy some new toys (welder) and gain valuable experience in a new endevor. Welding sheet metal in a floor is no where near as hard as doing it in a body pannel. Trace the new pan size, cut out the old sheet and lay in the new sheet and tack it in all around and then connect the dots. .025 wire and a bit of trial and error on a test piece and away you go... Give it a shot Spook, welding is a hoot.
Click to expand...

Actually from what I've been reading, it looks like I can get better results with a properly set up oxyacetylene torch (I do know how to use those!), #1 tip, some 3/32" ER70S-2 TIG rod and a steady hand. I'm hoping to be able to cut the floor close enough that I can just fuse weld, but we'll see how much luck I have with that.

Remember, this is a bit of a project car too. I bought it with this kind of stuff in mind.
 
Spook50 said:
Actually from what I've been reading, it looks like I can get better results with a properly set up oxyacetylene torch (I do know how to use those!), #1 tip, some 3/32" ER70S-2 TIG rod and a steady hand. I'm hoping to be able to cut the floor close enough that I can just fuse weld, but we'll see how much luck I have with that.

Remember, this is a bit of a project car too. I bought it with this kind of stuff in mind.
Click to expand...




That is going to require a lot more heat than a quick zap from a wire feed machine.


Get a 120V little wire feed machine and a bottle so that you do not have to screw around with flux core wire and sheet metal, and get it done.

Practice on some scraps, and you should have tacking things together down in pretty short order.


You will be glad that you did.


Torch welding sheet metal can be done, but you will put a lot more heat into the work and risk warping things far more than you will with a wire feed unit.


Good luck!

-Steve
 
Poser offers some really good advice. I have a welder and played around with some thin sheet metal. I have used flux core and gas and the gas is much cleaner. I didn't care and I warped the crap out of it. Get some scrap to pratice on first and do little tack welds and go slow. I'm no welder but its fun. That being said I am sending my 40 doors out to have the lower halfs replaced.
 
I always thought I'd have to farm out all of my welding when I bought my rusted ass 40. I was sick after getting some quotes so on a whim I bought a lincoln 135 and learned to weld with flux core. It took me some time but not hard by any means. Get a book. Lay down some beads. Take some pics and post them up with questions. To repair my 62 I will skip the flux core and use a bottle but the flux core worked fine on my 40. If its going to get covered up by your carpet anyway, what do you really have to loose?
 
I was in the same position about a year back, no welding experience, no pride, and a lot of interest and time. I spent some time in autobody dumpsters, finding nice flat hoods and quarter panels. I took them home, grinded off some paint, and practiced butt welds, and lap joints. I bought a panel flanger and worked hard to make my welds work with a stick welder. It can be done this way, though it is not pretty and not easy.

For your application, I would rent a mig with gas shielding (GMAW). You would have a very easy to use tool, and be able to get up to speed in reasonable time. Get a ton of metal ready to practice with, prep it so you can concentrate on the welding while the rental clock is ticking. Then weld away. Remember if the welds look sloppy, you can grind them down and fill.

there is my 2 cents.
 
have used strong magnets to hold the sheet in place, then tack to secure and fill in the gaps with longer beads, take time to let the sheet cool off after longer beads...
 
I find a lot of magnets and weights just don't get things tight enough, what I usually do is just put a hammer handle against it and lean on it while tacking, then tap and tack my way along
 
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