Sheetmetal welding question

[ashx2]

Forgive the ignorance, but I'm still learning on this.......

When you guys are welding, say, a rocker panel into place for instance......

Are you using a wire welder or what? Also when I see the pics I see that you're tacking say every couple of inches......do you go back and "fill" the rest of the bead and then grind it down?

Just not quite sure how this is done, and lord knows I need to get some information......I'm going to have to do it in the future.

Thanks guys!

Greg

[bac1755]

You need to use a wire welder, with solid wire do not use flux core on sheet metal. When body welding you dont want the metal to get to hot " it will warp" thats why you see tacks every so often and yes you go back and fill the gaps with more tacks. Just got to go slow.

[ashx2]

When you fill in are you doing so left to right or do you stay centered and do a kind of "jab & drag" method along the edge of the piece be welded?

Greg

[bac1755]

well you still want to tack, short bursts. You want to jump around on the piece. The less you warp the metal the better it will look and the less you have to bondo.

[bac1755]

There alot of videos on youtube on welding if you want a visual. Type in sheetmetal welding and go from there. it will help alot.

[ashx2]

I'd sure like to find somebody working on one our trucks fairly close, so I could go watch and learn first hand what to do and more importantly what "not" to do.

Greg

[my67chevytruck]

Theres plenty of build threads (including mine) to view showing the methods ...... there is also a rocker replacement 101 by LFD (kevin) in the FAQ section.

[Rudy67chevy]

Originally Posted by bac1755

You need to use a wire welder, with solid wire do not use flux core on sheet metal. When body welding you dont want the metal to get to hot " it will warp" thats why you see tacks every so often and yes you go back and fill the gaps with more tacks. Just got to go slow.

whats wrong with using flux core

[j_cst_10]

There is nothing wrong with using flux core, it just tends to penetrate deeper with the same voltage and wire speed settings. As long as you keep your heat under control there is nothing wrong with it.

[nickp51chevy]

Originally Posted by bac1755

You need to use a wire welder, with solid wire do not use flux core on sheet metal. When body welding you dont want the metal to get to hot " it will warp" thats why you see tacks every so often and yes you go back and fill the gaps with more tacks. Just got to go slow.

Exactly what he said, and make sure that you alternate sides. Tack at the top of the piece then tack on the bottom, then side to side.

[Sinister]

Originally Posted by Rudy67chevy

whats wrong with using flux core

You'll have to clean it up real well when you're done. The slag/residue from fluxcore can interfere with paint adhesion. That said I used fluxcore when I welded up my kick panel, I just hit it with a flap disc afterwards.

[msgross]

They might also have used plug welds in the pics you noticed. A rocker sits flush onto the edge of the floor. Holes are drilled into the rocker and then welded up, or plug welds, to hold in to the threshold of the door.

Get into the FAQ section and look for the rocker replacement 101 thread. Good pics and Kevin is a great welder.

FLux core is just a little messier than MIG welding. It really depends on what welder you have.. gas or no gas.

[bac1755]

Its alot easier to just use solid wire, and it works very well with a 75% argon 25% co2 gas. flux core wire on guage metal can hide alot of subsurface porosity. Yes it can be done but why mess with all the crap.

[ashx2]

A buddy of mine gave me a wire welder that runs off 110. It only has a hi/lo setting. Should I look into a different setup? I also have a cracker box that runs off 220, but I figure it'd be a little too much......maybe not.

Greg

[bac1755]

The cracker box is a stick isnt it? not for sheet metal welding.
That lil welder can get you started but it might just give you more proplems than you need, they dont weld very well.

[bac1755]

home depot sells a nice lil 220 lincoln mig for around 650.00 it will work nice for small projects. or save up and get a big boy that you will never have to up grade

[mrein3]

Technically there are reasons for using flux core wire over solid wire.

Recently I helped a friend rebuild his boat dock. The 16 foot pieces were too large to heft in and out of my shop next to my precious Chevelles so we had to cut and weld outside. Outside you can't use solid wire because the wind will blow the gas shield away. We HAD to use flux core.

You see your weld puddle can't be exposed to the atmosphere. If it is you'll get holes in the weld from the air oxidizing the molten metal. The flux, when it evaporates, creates a protected atmosphere around the puddle which protects the weld until it cools solid again. Inside the shop, with no air moving around, the gas from your gas bottle protects the puddle. Similarily when tig welding after you remove the tungsten you hold the torch there with the gas flowing for a second or two until the puddle cools.

[bac1755]

Originally Posted by mrein3

Technically there are reasons for using flux core wire over solid wire.

Recently I helped a friend rebuild his boat dock. The 16 foot pieces were too large to heft in and out of my shop next to my precious Chevelles so we had to cut and weld outside. Outside you can't use solid wire because the wind will blow the gas shield away. We HAD to use flux core.

You see your weld puddle can't be exposed to the atmosphere. If it is you'll get holes in the weld from the air oxidizing the molten metal. The flux, when it evaporates, creates a protected atmosphere around the puddle which protects the weld until it cools solid again. Inside the shop, with no air moving around, the gas from your gas bottle protects the puddle. Similarily when tig welding after you remove the tungsten you hold the torch there with the gas flowing for a second or two until the puddle cools.

If you use a gasless flux core I guess this is true, but in truth the wind can screw with that also. my opinion If your going to use gasless you might as well get a box of 6011 rods and break out the stick machine.

[67c-10Texas]

where are you located in centeral texas - you can come over and watch me learn on my cab

[chucks1967]

I am to still learning on the welder. I have a harbor freight 220 119 amp mig running flux. its really difficult to find that sweet spot on the welder settings. I tend to run it really low on wire speed and low on the voltage as well. Here is a couple pics of my attemps. They turned out.. ok, but guys the guys on here can tell me and you what I did wrong and how to fix that issue. I use the pull zig zag method on these.

[dfwright]

Originally Posted by ashx2

I'd sure like to find somebody working on one our trucks fairly close, so I could go watch and learn first hand what to do and more importantly what "not" to do.

Greg

Greg,

I don't know where you are in Central Texas (That covers a huge area, lol), but if you do get an opportunity to go and learn first hand, If I can, I would love to join you. I am in the same boat you are, I've read lots of threads on welding, watched some videos on youtube, and read several good technical articles on welding, but I have yet to draw an arc on sheet metal, and would love the opportunity to watch and learn the correct procedures

[67c-10Texas]

sorry, i am in san marcos. i have shaved the fuel filler, currently shaving the driprails and filling the stake pockets in the bed -

i will try to post pictures of the progress

[Skirkpat]

Originally Posted by Rudy67chevy

whats wrong with using flux core

Flux core is fine on anything that you are not putting a finish coat of paint on...That flux will become part of the weld bead, cannot be completely removed and will affect paint adhesion...if you pay for decent paint use the right welder, Tig preffered, Gas shielded Mig if that's what you have.

[sneakysnake]

[QUOTE=Skirkpat;3284353]Flux core is fine on anything that you are not putting a finish coat of paint on...QUOTE]

A good primer, preferably epoxy will solve that.




Flux core splatters more and the beads arent as pretty. Ive found for spot welding it works fine and your gonna grind off the excess anyway so its pretty when you get through.The trick to body metal welding is knowing where and when to bead and when to spot and tread lightly to reduce heat and warpage.

[tim21391]

check out my build thread..you will see the holes i drilled to attach my rocker panel