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> Repairing Engine Tin, A newbie's lesson in welding
seanpaulmc
post Feb 22 2021, 07:20 PM
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I recommend all new welders to get some 50 year old thin gage sheet metal to learn with. (IMG:style_emoticons/default/welder.gif) How hard could it be?

In doing so, you’ll practice with voltage and wire speed, stick out, part set up, metal cleaning, contamination and porosity, work area lighting, youtube, weld grinding, fabrication, clamping, gapping, blow thru, backing materials, warping, patience and wire brushing, to name a few.

What I have...
How many cracks can you spot?

Attached Image

Attached Image

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Save your original OG engine tin they say. It's the best they say.

So after a few hours...
I'm not kidding anyone here with these pictures, after many days I find myself with this...

Attached Image

Attached Image

Attached Image

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I have several questions for those with at least a few hours more experience.

1) How much more, if any, should these welds be ground down? Or, will the weld beads provide future strength to the thin, stretched sheet metal so leave as-is?

2) In order of preference, what would be the best three tools to use to grind down welds on thin sheet metal? Assume you don't have an air compressor. I don't.

3) For the top section where the coil attaches on the tin, the coil bracket uses P/N: N 010 210 13 which is M 6 x 10 hex-head bolt. Is the tin supposed to have a captured nut on the backside or just thicker sheet metal in the locations that are missing on my tin (see first few pictures).

4) Should the coil mounting location be relocated in order to avoid whatever the hell happened here? If so, where?

In actuality I'm quite please with the results so far, maybe not the pace of the work, but at least the product thus far. It'll be useable tin and certainly better than it was. (IMG:style_emoticons/default/screwy.gif) This is literally the first time I have ever fabricated a patch and tried to weld anything. I'm working my way up to the easy stuff if there such a thing?

I appreciate you entertaining my questions.

Thanks,
Sean



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Archie
post Feb 22 2021, 07:54 PM
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QUOTE(seanpaulmc @ Feb 22 2021, 05:20 PM) *

I recommend all new welders to get some 50 year old thin gage sheet metal to learn with. :welder: How hard could it be?

In doing so, you’ll practice with voltage and wire speed, stick out, part set up, metal cleaning, contamination and porosity, work area lighting, youtube, weld grinding, fabrication, clamping, gapping, blow thru, backing materials, warping, patience and wire brushing, to name a few.

What I have...
How many cracks can you spot?

Attached Image

Attached Image

Attached Image

Save your original OG engine tin they say. It's the best they say.

So after a few hours...
I'm not kidding anyone here with these pictures, after many days I find myself with this...

Attached Image

Attached Image

Attached Image

Attached Image


I have several questions for those with at least a few hours more experience.

1) How much more, if any, should these welds be ground down? Or, will the weld beads provide future strength to the thin, stretched sheet metal so leave as-is?

2) In order of preference, what would be the best three tools to use to grind down welds on thin sheet metal? Assume you don't have an air compressor. I don't.

3) For the top section where the coil attaches on the tin, the coil bracket uses P/N: N 010 210 13 which is M 6 x 10 hex-head bolt. Is the tin supposed to have a captured nut on the backside or just thicker sheet metal in the locations that are missing on my tin (see first few pictures).

4) Should the coil mounting location be relocated in order to avoid whatever the hell happened here? If so, where?

In actuality I'm quite please with the results so far, maybe not the pace of the work, but at least the product thus far. It'll be useable tin and certainly better than it was. :screwy: This is literally the first time I have ever fabricated a patch and tried to weld anything. I'm working my way up to the easy stuff if there such a thing?

I appreciate you entertaining my questions.

Thanks,
Sean


Hello Sean,
Regarding the welding techniques, please allow me to point you in THIS direction: https://www.youtube.com/watch?v=34bPn6lfyuA...f_g&index=4
He has an absolute encyclopedia of YouTube videos covering all aspects of bodywork welding and stuff with many handy tips and tricks which I dearly wish I'd known about when I started welding! ! Your welds don't look half-bad by the way! I'm a great believer in the no body-filler school of thought but it's tough to achieve.

To your questions:

1) I like to grind them down as much as possible, but that's just me!

2) See Trev's blog. He recommends a super-coarse flexible disc. I like an electric belt-sander as you can follow the weld bead.

3) There are two captive nuts, if memory serves.

4) I'll pass and let more knowledgeable types chip in.

Good luck and best wishes!


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Posts in this topic
seanpaulmc   Repairing Engine Tin   Feb 22 2021, 07:20 PM
Archie   I recommend all new welders to get some 50 year o...   Feb 22 2021, 07:54 PM
cary   3" 36gr RoLoc on a 2" pad. Gives you a f...   Feb 22 2021, 08:34 PM
malcolm2   Paint 'em and drive it.   Feb 22 2021, 10:51 PM
rfinegan   I just spent a few hours on mine last night. And ...   Feb 23 2021, 04:51 AM
Mark Henry   Take a section of copper sheet or copper pipe and ...   Feb 23 2021, 08:26 AM
Archie   Take a section of copper sheet or copper pipe and...   Feb 23 2021, 07:21 PM
Mark Henry   Take a section of copper sheet or copper pipe an...   Feb 24 2021, 08:56 AM
ClayPerrine   [quote name='Archie' post='2894103' date='Feb 23 ...   Apr 8 2021, 11:17 AM
Robarabian   Yes on the copper. Also, where you see the nice ri...   Feb 24 2021, 09:09 AM
rfinegan   Got this a Harbor Freight for a few bucks....   Feb 24 2021, 09:26 AM
dr914@autoatlanta.com   the passenger side 2.0 engine cylinder cover is im...   Feb 24 2021, 10:09 AM
Mark Henry   the passenger side 2.0 engine cylinder cover is i...   Feb 24 2021, 10:46 AM
Superhawk996   Like this one? BTW I have the other side as wel...   Feb 25 2021, 06:58 AM
Mark Henry   [quote name='Mark Henry' post='2894247' date='Feb...   Feb 25 2021, 08:41 AM
Superhawk996   The dies used to pop these pieces out were quite...   Feb 25 2021, 09:31 AM
Shivers   The dies used to pop these pieces out were quit...   Apr 8 2021, 10:05 AM
Jett   Like this one? BTW I have the other side as we...   Feb 25 2021, 09:10 AM
Superhawk996   [quote name='Mark Henry' post='2894247' date='Feb...   Feb 25 2021, 09:51 AM
Jett   [quote name='Mark Henry' post='2894247' date='Fe...   Feb 25 2021, 12:31 PM
914_teener   the passenger side 2.0 engine cylinder cover is ...   Feb 25 2021, 09:26 AM
Bleyseng   [quote name='Mark Henry' post='2894247' date='Feb...   Apr 7 2021, 08:20 PM
seanpaulmc   Hello Mark Henry - Could you scoot that tin arou...   Apr 7 2021, 06:06 PM
Mark Henry   Hello Mark Henry - Could you scoot that tin aro...   Apr 8 2021, 09:32 AM
bkrantz   For grinding welds on sheet metal I like flappy sa...   Feb 24 2021, 10:02 PM
bbrock   For grinding welds on sheet metal I like flappy s...   Feb 25 2021, 08:37 AM
bbrock   I never thought about it before but that right fro...   Feb 25 2021, 08:49 AM
VaccaRabite   What I want to know is - what on earth caused thos...   Feb 25 2021, 09:52 AM
Superhawk996   What I want to know is - what on earth caused tho...   Feb 25 2021, 09:58 AM
Mark Henry   What I want to know is - what on earth caused tho...   Feb 25 2021, 10:01 AM
914sgofast2   What I want to know is - what on earth caused th...   Apr 7 2021, 06:52 PM
seanpaulmc   The area of concern I have for this piece of tin i...   Apr 8 2021, 11:42 AM
Mark Henry   The tin is correct in that area, you're good t...   Apr 8 2021, 11:45 AM
wonkipop   mate you are a hero for working out how to do thi...   Apr 9 2021, 04:09 AM
930cabman   mate you are a hero for working out how to do th...   Apr 9 2021, 05:01 AM


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