37 replies to this topic

[Notay]

Hi, I am replacing the side section of the boot floor as they were rusted.

 

I am trying to butt weld the pieces together. I made the mistake of using frost clamps in between the two panels to be butt welded together and so there is a large gap and for thin metals and butt welding, this is not the best thing. I should not have put a gap in between as the many searches on google have suggested, but o well.

 

Anyway, as you can see I keep blowing a hole between the two panels since the gap is large even when the welding settings are at there lowest amps. I thought about using a copper piece behind the panel to help disperse the heat but have no idea how to hold it up against the panels when welding. I have already started plug welding it to the arch so don't wish to remove the panel.

 

Can someone please help me on this? I have uploaded some pics. Many thanks in advance.

 

Notay

Attached Files

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[rally1380]

Copper bar definately works.....how bout holding it with strong magnets?

[rally515]

I'm afraid if you,ve cut off too much you can't shrink the gap back down like a wizard, some things you can do though are along the lines of using welding wire to fill the gap, turn your gas off and press the trigger till a nice long enough piece of mig wire runs out, clip off and place into the gap you,ve made, now turn the gas back on and tack weld the wire in between the panels, this should aid your problem but by no means aa straight cure, it'l still be a bit tricky here and there but i'm afraid you'll have to bare with it and learn from your mistakes.

 

This is my solution and don't take it as gospel ;)

 

Cliff

[Carlos W]

You can get some really funky clips! 

 

Be right back

[Carlos W]

http://www.ebay.co.u...=item589af72d30

[sonikk4]

You should be able to pulse weld that gap. looking at your picture that is the size of gap you get when you use intergrips. Don't try and seam weld it.

[rally1380]

You should be able to pulse weld that gap. looking at your picture that is the size of gap you get when you use intergrips. Don't try and seam weld it.

 

Agree...have MIG welded gaps like that without too much of an issue.

[Notay]

Hi, I tried pulse welding first with a tack, but its the tack that keeps blowing through. I am using 0.8mm wire if that helps.

[Notay]

and yes that is the intergrips gap size

[sonikk4]

Sounds like the wire is too thick. I use 0.6mm on panels and have no problem with that at all. 0.8 may need too much power to form a decent tack.

 

I will be doing an inner sill replacement tomorrow using that wire gauge so will post up pictures.

[rally515]

The wire is fine, check your amp's Notay, sounds like you're running far too high, practice makes perfect and do abit of testing before giving up and scratching your head, theres always a way ;)

[Notay]

yea thought about the wire being too thick. I will give it a shot tomorrow on 0.6mm. Is there a technique to butt welding with that sort of gap size?

[Carlos W]

yea thought about the wire being too thick. I will give it a shot tomorrow on 0.6mm. Is there a technique to butt welding with that sort of gap size?

 

 

Pulse, decent gap, pulse, decent gap

 

Then start at the first one, pulse, along to the next etc

 

Gives the panel time to cool

[Shifty]

Is that gasless or gas?  0.8 is probably a bit big really, some people do prefer it but generally 0.6 is better

 

Don't aim the wire towards the gap, try and get it on either the top or the bottom and then fill the gap, so aim at the top and then flick the weld down

 

)))))))))

 

Kind of like the pattern above.

[Notay]

The wire is fine, check your amp's Notay, sounds like you're running far too high, practice makes perfect and do abit of testing before giving up and scratching your head, theres always a way ;)

practice does make perfect....looks like I need a lot of practice!