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> Some progress at last!, let the welding begin...
gaz914
post Jan 2 2005, 06:38 AM
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Well after looking at all the great pics of everyone else's project, I finally got myself a MIG welder and a cool auto-darkening welding helmet.

Practised on some scrap first then bit the bullet and moved to the real thing.

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.gaz914.com-1758-1634533814.1.JPG)

Only minor stuff first.

Weld up holes in sail panel.

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.gaz914.com-1758-1634533814.2.JPG)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.gaz914.com-1758-1634533814.3.JPG)

More Pics soon <!-- emo&:clap: -->(IMG:http://www.914world.com/bbs2/html/emoticons/clap.gif)<!-- endemo -->

2005 Year of the Tangerine <!-- emo&:trophy: -->(IMG:http://www.914world.com/bbs2/html/emoticons/smilie_pokal.gif)<!-- endemo -->
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Rhodes71/914
post Jan 2 2005, 10:32 AM
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Cool, Looks like I need to get myself a welder, finally have an excuse now.
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RustyWa
post Jan 2 2005, 01:59 PM
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I was in the garage last night practicing my welding as I've got to weld in the triangle reinforcement pads for the front swaybar. I did some real nice practice welds on the bench. I was feeling pretty good as they were some of my best.

Then I remembered that I'll need to do vertical welds. So I practiced doing vertical and boy was that humbling. My welds turned back to crap. I couldn't control the puddle as it would keep falling out.

I ran out of gas so I'll have to wait to practice some more. If anyone has tips for welding 16-18 ga. material vertical...I'm all ears.


(IMG:http://www.914world.com/bbs2/html/emoticons/welder.gif)
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gaz914
post Jan 2 2005, 11:29 PM
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Welded up the hole for the lamp on the RHF fender.
Still needs some more smoothing.

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.gaz914.com-1758-1634533903.1.JPG)

Started investigating the rust in the cowl area <!-- emo&:huh: -->(IMG:http://www.914world.com/bbs2/html/emoticons/huh.gif)<!-- endemo -->
It had rusted in the usual place where the fender meets the cowl.
The rest of the fender is pretty much perfect so I was not intending to remove it.
Good news is that the rust hasn't spread to the actual tub <!-- emo&:D -->(IMG:http://www.914world.com/bbs2/html/emoticons/biggrin.gif)<!-- endemo -->

Don't know if it's better or worse now though <!-- emo&:headbang: -->(IMG:http://www.914world.com/bbs2/html/emoticons/headbang.gif)<!-- endemo -->

Any repair technique suggestions welcome.

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.gaz914.com-1758-1634533903.2.JPG)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.gaz914.com-1758-1634533903.3.JPG)
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Rhodes71/914
post Jan 2 2005, 11:38 PM
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Sorry I can't help you with any advice cause I'm new to rust repair as well. But I saw that you are an Aussie and I'm sitting here drinking a Coopers Brewery Best Extra Stout that my in-laws brought me and it ain't bad. This considered decent stuff there? (IMG:http://www.914world.com/bbs2/html/emoticons/beer3.gif)
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gaz914
post Jan 3 2005, 02:36 AM
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QUOTE (Rhodes71/914 @ Jan 2 2005, 09:38 PM)
Sorry I can't help you with any advice cause I'm new to rust repair as well. But I saw that you are an Aussie and I'm sitting here drinking a Coopers Brewery Best Extra Stout that my in-laws brought me and it ain't bad. This considered decent stuff there? (IMG:http://www.914world.com/bbs2/html/emoticons/beer3.gif)

Coopers is" decent stuff" here (IMG:http://www.914world.com/bbs2/html/emoticons/beerchug.gif)

The "boys" have one or two on Christmas Day every year before we start on the red wine (IMG:http://www.914world.com/bbs2/html/emoticons/smile.gif)
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Jason914
post Jan 3 2005, 05:43 AM
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Looking good! I was planning to purchase a Lincoln Mig Pak 10 welder. But, I saw that Eastwood Company sells a Spot and Stitch Welding Set for Arc Welders (cheaper). It's at this link: Spot And Stitch Welder Set With Rods. What do you guys think about this setup?

Jason
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lapuwali
post Jan 3 2005, 12:09 PM
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I bought one of those, primarily because the job I need to do will specifically require spot welding from one side of the panel, which this setup is ideal for. However, for general purpose use, a MIG welder is much easier to use, and you can "spot" weld with one by drilling a hole in one panel and rosette welding through the hole. Stick welders are cheap, but they're probably the most difficult of all of the welder types to use. I'll probably end up getting a MIG when I need to do something that requires much seam welding on panels. I'll probably give the stitch welder a try, but I'm not going to care much if I can't make it work well. The spot welder bit is worth the price by itself.
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gaz914
post Jan 5 2005, 04:09 AM
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I like staying home from work - lets me do some REAL work (on the teener) <!-- emo&:D -->(IMG:http://www.914world.com/bbs2/html/emoticons/biggrin.gif)<!-- endemo -->

POR 15'd the cowl after cleaning up the rust and welding up some holes.

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.gaz914.com-1758-1634533991.1.jpg)

Made up some pieces to repair the inner fender and welded them in.

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.gaz914.com-1758-1634533991.2.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.gaz914.com-1758-1634533991.3.jpg)

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.gaz914.com-1758-1634533991.4.JPG)

The only way I could think to do it was to use two pieces.
The first vertical piece (green highlight) was welded to the remains of the inner fender.
Then a patch was welded to fill up the hole (orange highlight).
Not the best job in the world but it won't be seen when the outer skin is repaired.

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.gaz914.com-1758-1634533992.5.jpg)

POR 15'd that as well

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.gaz914.com-1758-1634533992.6.jpg)

Now just have to make some pieces to fix the cowl and the outer skin of the fender.
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xsboost90
post Jan 5 2005, 05:59 AM
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wow, that looks just like what i did! Except here was my solution for making the last piece! (IMG:http://www.914world.com/bbs2/html/emoticons/sawzall-smiley.gif)


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xsboost90
post Jan 5 2005, 06:01 AM
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i did the same thing w/ the markers and the tops of the fenders, except i have still to weld up some small holes in the lower fender area, seems to be a PITA.


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Root_Werks
post Jan 5 2005, 10:03 AM
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QUOTE (RustyWa @ Jan 2 2005, 11:59 AM)
I was in the garage last night practicing my welding as I've got to weld in the triangle reinforcement pads for the front swaybar. I did some real nice practice welds on the bench. I was feeling pretty good as they were some of my best.

Then I remembered that I'll need to do vertical welds. So I practiced doing vertical and boy was that humbling. My welds turned back to crap. I couldn't control the puddle as it would keep falling out.

I ran out of gas so I'll have to wait to practice some more. If anyone has tips for welding 16-18 ga. material vertical...I'm all ears.


(IMG:http://www.914world.com/bbs2/html/emoticons/welder.gif)

Sounds like you are letting the metal "pool" a little too much. The easiest welding to do of course is like you are welding on the floor facing down. It gets harder as you turn to hot metal dripping as you weld above you.

Try shorter bursts. Give the metal a second to cool and stop flowing so much. Zap, zap, zap sort of thing. Not ZAaaaaaaaaaaaaaaaaaap. (IMG:http://www.914world.com/bbs2/html/emoticons/welder.gif)
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spunone
post Jan 5 2005, 11:57 AM
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Heard there's a softer wire to use when doing body work so as much easier to sand is this true and where do we get it ??? (IMG:http://www.914world.com/bbs2/html/emoticons/welder.gif)
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914GT
post Jan 5 2005, 12:26 PM
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I don't know the difference between mild steel and low alloy wire when it comes to ease of grinding welds. Your local welding supplier will have the wire and may know if one is easier to grind/sand than the other. You can buy wire online also. One thing I have noticed though - welds are easier to grind when using CO2 gas rather than the Argon/CO2 blends. Each gas has their benefits depending on your requirements.
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restore2seater
post Jan 5 2005, 01:10 PM
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QUOTE (spunone @ Jan 5 2005, 09:57 AM)
Heard there's a softer wire to use when doing body work so as much easier to sand is this true and where do we get it ??? (IMG:http://www.914world.com/bbs2/html/emoticons/welder.gif)

Maybe talking about this wire.
20 Gauge
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J P Stein
post Jan 5 2005, 01:30 PM
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I use a product called "Easy Grind"..... .024.....for auto sheet metal. It's just that, somewhat easier to grind.
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gaz914
post Jan 7 2005, 12:23 AM
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No progress on Thursday - Did this instead <!-- emo&:driving: -->(IMG:http://www.914world.com/bbs2/html/emoticons/driving.gif)<!-- endemo --> (I'm in the 2nd car in 1st pic)





Basically they throw the circuit open for the day and you get a number of 20 minute sessions (feels like about 5 minutes).

Through the little kink at about 140 km/h (80 mph).


Trail brake to get the back moving out a bit


This bloody Mustang wouldn't move over and let me past. I was much faster through the twisty bits and could even keep up down the straight, just wasn't fast enough to actually pass him.


Other cars have caught up now


Braking hard into turn 1 from about 80 mph
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gaz914
post Jan 7 2005, 12:33 AM
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Today I made a new piece for the cowl area.
I am sure it isn't EXACTLY the shape that came from the factory but I am reasonably pleased with the result. And it took me most of the day to do <!-- emo&:headbang: -->(IMG:http://www.914world.com/bbs2/html/emoticons/headbang.gif)<!-- endemo -->

(IMG:http://www.914world.com/bbs2/uploads_offsite/www.gaz914.com-1758-1634534941.1.jpg)

This thread has been invaluable in getting the cowl back into shape.
Pics of front trunk thread

Hopefully I will have finished the RH fender before I go back to work on Monday <!-- emo&:( -->(IMG:http://www.914world.com/bbs2/html/emoticons/sad.gif)<!-- endemo -->
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SpecialK
post Jan 7 2005, 02:39 AM
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Enough playin' gaz914 (if that is your real name (IMG:http://www.914world.com/bbs2/html/emoticons/wink.gif) ), I want to see how this turns out!

I seriously like the one piece fender/cowl look xsboost90 has going there. Plus, it's one less rust trap.....considering that look myself (no concourse...previously molested, she's been around!

So what the hell (IMG:http://www.914world.com/bbs2/html/emoticons/welder.gif) )


Seriously...Great to see pics of progress!
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gaz914
post Jan 7 2005, 07:05 AM
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QUOTE (Special_K @ Jan 7 2005, 12:39 AM)
I seriously like the one piece fender/cowl look xsboost90 has going there.  Plus, it's one less rust trap.....considering that look myself (no concourse...previously molested, she's been around!


Yeah it is tempting to just go to town and (IMG:http://www.914world.com/bbs2/html/emoticons/welder.gif) and make the "clean" look like xsboost90 has done, but there is the "do it right" part as well... (IMG:http://www.914world.com/bbs2/html/emoticons/unsure.gif)

Just have to have a go and see how it turns out (IMG:http://www.914world.com/bbs2/html/emoticons/biggrin.gif)
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