55 Wagon Progress

[MP&C]

Some more cleanup work on the roof weld, didn't get much for in process pictures, but then this part gets pretty boring anyhow...








Inside...





I'm pretty pleased with how it turned out this time. Still has some metal bumping needed to address some highs and lows, which we'll work on next time in the shop, as well as welding in the last pieces of the lift gate..

[Bomp]

Originally Posted by MP&C

Some more cleanup work on the roof weld, didn't get much for in process pictures, but then this part gets pretty boring anyhow..

I feel like a total Newbie watching your work. Boring or not Im sopping up every boring detail.
One question though, what did you use to smooth out the inside of the roof? Did you use the same tool to finish out the outside (top) of the roof?

May be boring to you but life changing to me.

[MP&C]

On both inside and out I start out by knocking down the proud of the weld in between dots using a 3" x .035 (or 1/16 thick if that's what you have) cutoff wheel held perpendicular to the weld. This both gives a minimal contact patch for less heat buildup but also gives the most unobstructed view of any device used to grind down the weld, so you have less chance of inadvertently hitting the panel on either side of the weld, thinning out the panel..

See here for the grinding method, this is on a plug weld but the grinding process is the same:


https://www.youtube.com/watch?v=V2WHT_zMOE8

After getting the bulk of it down on the entire weld, a 3" 80 grit roloc sander is used on the outside to dress the panel, and on the inside an 1-1/2" diameter drum sander is used to clean up the high spots and finish with the same 80 grit roloc. Not saying this is the right way or the only way, but it's what has worked best for me.

[ljackson]

Originally Posted by MP&C

After getting the bulk of it down on the entire weld, a 3" 80 grit roloc sander is used on the outside to dress the panel, and on the inside an 1-1/2" diameter drum sander is used to clean up the high spots and finish with the same 80 grit roloc. Not saying this is the right way or the only way, but it's what has worked best for me.

Thanks for the previous explanation. I have a question about the drum sander. I am thinking this tool. Is this what you mean?

[MP&C]

Yes, exactly. I have the 3/4 and 1-1/2 diameters.




Got tired of buying the drums by the 3 pc blister pack at the local True Value, so my welder supply ordered me SAIT in boxes of 100 qty of 60, 80, and 120 grit... Cheaper per drum and better quality

[ljackson]

Originally Posted by MP&C

Yes, exactly. I have the 3/4 and 1-1/2 diameters.

Got tired of buying the drums by the 3 pc blister pack at the local True Value, so my welder supply ordered me SAIT in boxes of 100 qty of 60, 80, and 120 grit... Cheaper per drum and better quality

Thanks for reply and the supplier tip.