914-6/904 project begins Options

[Unobtanium-inc]

One last thing my number is in my signature I would be happy to talk with you , give pointers, etc.. My biggest critic is proper prep of the weld areas, proper but joints, cut materials with plasma or oxy torch as a last resort and use shear and cut off wheels as standard.


I am absolutely sincere in my offer. Give me a call.

Thanks for the tip, I use either air shears or a cut off wheel, I don't have a plasma cutter. I do need to find a better way to prep some of the hard to reach spots. I've been using a die grinder with a 3" disc, but my body guy showed me one of his tools, I might have to get one. They are pricey, but good tools always are.

[mb911]

Dyna file or the likes is whats pictured. The 4-1/2" hand grinder with a.045 cut off wheel works really well.. The debur with the dyna file.

[mb911]

Also a 90 degree angle grinder with a roloc setup for sanding discs, scotch brites work awesome.

[Unobtanium-inc]

Also a 90 degree angle grinder with a roloc setup for sanding discs, scotch brites work awesome.

Thanks!

[Bruce Hinds]

Plenty of us are enjoying the build Adam, don't let them bring you down to their level on this thread. Hard to ignore I know, but you're time is better spent in the shop. It seems people like that will just try to keep the banter going . . . Or, you could get some enjoyment out of this if you're like me. "What can I cut next to really piss someone off?"

[KELTY360]

Well said Adam. The negative responses to your thread are one of the most disappointing things I've seen on 914World. As a whole, when someone takes on a massive project this group is supportive and objective; offering constructive criticism and encouragement. In your case you've been treated rudely for further modifying an already heavily modified car which had apparently outlived it's usefulness...unless you were expected to restore it to some previous level of modification.

Generally, the prevailing attitude is: "it's your car, do what you want with it." But with you, there is a certain segment of '914 Purists'....now there's an oxymoron....who can't stand seeing someone trying to follow an audacious vision. Maybe I'm simple minded, but I don't get the vituperation against another member who has been forthright in his intentions from the start. I think you've been very patient with the naysayers in spite of their repeated rude, non-constructive behavior towards you personally.....on your own thread. In my own humble opinion, the adults need to check their attitudes at the door or as you suggest, start their own bashing thread. The children should just STFU.

I hope you'll continue to ignore the a-holes among us and persevere. You may even learn to be a better welder.....not that I have any right to critique. (IMG:style_emoticons/default/shades.gif)

[bretth]

I wish an admin could come in and clean the garbage out of this thread. It has been done on 914 world before but it appears only some personal favorites are afforded this allowance. I know now that I will never post a build thread on here and I am sure there are others who feel the same. Bunch of adult babies ruining what this site used to be.

Brett

[simonjb]

I love this forum - and I am relatively new here - but its a shame about all these negative posts. Remember what your Mother said (or should have said) - if you don't have anything nice to say then don't say anything at all. It does nothing but cause grief.

Adam, keep posting. Its fun to see and read.

[Jonathan Livesay]

(IMG:style_emoticons/default/popcorn[1].gif)

[SirAndy]

Looks like this thread is ready for a cleanup but i'm currently at work and have no time to weed through 39(!) pages.

(IMG:style_emoticons/default/headbang.gif)

[bbrock]

I know now that I will never post a build thread on here and I am sure there are others who feel the same.

I vowed to stay out of this thread but this comment hits hard and I feel I need to chime in. Honestly, I get where both sides are coming from and confess that I've been confused here myself. But I strongly agree that constructive criticism is what this is all about and putting everything else aside, Adam has responded well when it is offered.

To think this thread might dissuade others from staring there own build thread is a travesty. I've been here less than a year and have come to regard my build thread as one of the most important tools I have for my restoration. It is equally important as is my welder, grinder, and body hammer IMHO. And the build thread is a two-way street. It helps both the person doing the build and the many who read it. There is no way I'd have gotten as far on my build as I have without the many build threads that went before, or the advice I've received.

I have my own opinions here, but what's done is done. The race car is dead. It seems the best possible outcome going forward is to help Adam create a kick ass 904 tribute. If not for this project, do it to encourage other people to share their work! (IMG:style_emoticons/default/beerchug.gif)

[johnhora]

I couldn't find the sports car of my dreams, so I built it myself.
Ferdinand Porsche


Adam....Keep building Brother!

[Unobtanium-inc]

Ok, so I'm going to go with the Aye's won, and the Nay's can....

With that over, let's get back to the build.
After taking the criticism from two other members about the dirty welds I went back and wanted to see what might have changed in my procedure and or materials. I remembered I hate changed steel suppliers recently. So while my old flat steel had a light coating that was weld through, the new stuff did not. if you look at the cleaned photo you can see where a pretty thick coating came off. Live and learn. I also added some more tools to the cleaning arsenal.
The piece went in really well and fit nicely. The welds came out much cleaner. It was still tricky towards the bottom, welding at funny angles and upside down, but I was happy with the results.
Hopefully I can make some time tomorrow too.

And thanks to everyone for your support on the build, it really means a lot. And thanks again to Rich and Ben for pointing out the dirty welds, aren't forums great!

[tygaboy]

Adam - Some observations from the West Coast...

The original sheet metal you used looks to be hot rolled, a process that leaves that nasty coating, is messy to weld, etc. You want cold rolled.

What gauge material are you using? It could be the pics but it looks far thicker than the chassis material. I'd think you'd want 18ga.

When adding those panels to replace/reinforce the frunk firewall, if you're not going to butt weld them and will be lap welding as you are, you might consider spot welding them in.
I'd be willing to bet that with the full seam welds you're using, you're moving the chassis around in ways you may not want. At the very least, I'd add bracing to prevent things moving.

You could also add some beading to give the panels some section to add stiffness, especially in any of the larger, flat panels.

Another option would be to add closed sections (folded sheet metal or square tube, maybe?) to form a more suitable opening that you'd then close with the sheet metal. You may find you can work with smaller, simpler pieces to address the more complex areas and that'll make it easier, overall, to complete a particular area.

If one is better at metal forming, then make fewer pieces, if one is better at welding, make more pieces and weld them together. In the end, it's essentially the same result.
(I'm living this very thing as I tackle my custom fire wall.)

Hope you find this useful.

Maybe see you next week at Wray's.
Chris

[mb911]

Adam,

What is your welder setup ? Wire diameter, brand and model? What welding helmet are you using again? This will help me guide you a but more. Looks like your current setup maybe askew.. If we can help with that then the rest falls into place a bit more..


One of my favorite new welding helmets is the miller t94. It has good off welding vision to allow for good placement of the electrode and turns up or down in half shades.

Another point would be that for your panels intermittent welds maybe all thats needed so a full seem weld may not be needed. I would lay out where the welds need to go about every 1.5" for a 3/4" bead. This will make the parts plenty strong and save time on clean up..

[tomeric914]

Another point would be that for your panels intermittent welds maybe all that's needed so a full seem weld may not be needed. I would lay out where the welds need to go about every 1.5" for a 3/4" bead. This will make the parts plenty strong and save time on clean up..

(IMG:style_emoticons/default/agree.gif)

Also slow down your wire feed and maybe bump the voltage up a notch. It should sound like bacon frying when the speed and voltage are right and the welds should lay fairly flat.

Other factors that will affect your welds are how far you're away and whether you're pushing or pulling the electrode.

I did a quick search and found this video on wire speed and voltage that isn't half bad if you've got a few minutes (don't be fooled by the goofy still image, it's legit):


https://www.youtube.com/watch?v=sZuq4XQTHVs


From a material perspective, it looks like you might have picked up some black iron which needs a lot of cleaning to weld right as you have discovered.

With the settings right, you'll have a lot less grinding to do when it's all done.

Lastly, I'm not sure where your shop is but am willing to help if you're not far away. I'm located near Syracuse.

[mb911]

Remember voltage is = to gears you can only go so slow/ fast in each gear without changing to another gear to faster or slower

Wirespeed is = to gas pedal. It will only go so fast until you run out of gear and you need again shift gears

They should be paired. The biggest mistake people make is think that to make a weld hotter is to turn the voltage up without knowing that voltage is potential amperage and wire speed is actual amperage= heat.

[jd74914]

I did a quick search and found this video on wire speed and voltage that isn't half bad if you've got a few minutes (don't be fooled by the goofy still image, it's legit):


https://www.youtube.com/watch?v=sZuq4XQTHVs

That guy's (Jody) podcast is really good, as are his videos. Definitely recommended.

I would switch to a flap disc on your grinder for cleanup. Or even a knotted wire wheel. Those cup brushes suck IMO. I've never liked how they seem to unbalance the grinder either.

Going to join Chris here and say your metal is way heavier than needed as well. From this view it looks ~0.100" thick; you would likely be just fine with 0.050".

[Unobtanium-inc]

To answer everyone's question about my welding setup. I'm using a Millermatic 135. I normally have the settings at about 33 for wire speed and around 3 for voltage. I have to lower everything when I'm welding on really rusty 356's, too much just blows holes in the side of a car. My welding helmet is your standard Northern Tool auto-darkening helmet, not a big fan of the flames. The metal I'm using is 16 gauge, which is what I normally use.

Any advise on any of these I am all ears. Anything I can do to improve my process would be great and I know there is a lot of talent on this board.

[mb911]

16ga is too think and it is hot rolled which makes your job harder. What is your wire diameter?