Hmmmmm..........A couple of burns, lungs full of welding fumes, eyes still seeing an arc and high from burning seam sealer fumes...........what could be more fun!

It took 7 hours, but it's done. Hopefully it won't twist like a pretzel when I finally get to punch the 3.6!

Passengers side............

Drivers side...........

Firewall...................

Way to go

Fun, huh?


KT

My concerns would be rusting between the original and new metal pieces. What do you do to protect the sandwiched metal?

Personnaly,

I'd spray the sh*t out of it with that 95% ground zinc/5% binder spray that rustoleum sells (ZincSele?) Stuff is conductive and you can weld through it

Zinc acts as a sacrificial anode to steel and prevents rust. Zinc plated parts form a ring of melted zinc around the spotweld and protect it.

Since you are doing rosettes rather than spot welds, you prolly will get some melted zinc at the edge of the melted metal. Having a conductive layer of zinc between the layers is a good thing.

That being said, ZINC FUMES ARE POISONOUS and can cause zinc fever. Weld outside and wear a painting mask with an activated charcoal filter

Ken

Has anyone used Bloxide? I just used it for some small stuff on the 914. Worked pretty well I just don't know about the longterm implications. It's aluminum floating in something. It's conductive so you can weld through it.

Never used bloxide but here is what it says..

"Bloxide - The preferred weld-through primer. This Aluminized de-oxidizing primer insures x-ray quality welds. Promotes the formation of Aluminum oxide at the weld site to reduce porosity. Prevents corrosion of coated steel surfaces for several months of outside storage. Easy brush or spray-on (no thinning required) application Bloxide Qt. (16055ZP)application. For longer-term corrosion prevention use Zinc Rich, Cold Galvanizing Compound Qt (16005ZP)."

So, for long term corrosion protection, you are back to zinc cold galvanizing (ZincSelle)

Ken