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| Welding help... https://www.ausmini.com/forums/viewtopic.php?f=2&t=47028 |
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| Author: | IwannaMini [ Mon Oct 27, 2008 10:50 am ] |
| Post subject: | Welding help... |
Can someone explain something to me... When you weld two panels together, they have the seams, so you spot weld them, smooth over etc etc... Same with floor pans etc. If you are not replacing a panel but want to cut rust out and "extend" the existing panel, how do you do this cleanly? I have cut some rust out of the rear windows for the panel van and now need to get the windows back in... thanks..! 
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| Author: | Trixitrine [ Mon Oct 27, 2008 11:06 am ] |
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depends how big the hole is... what part of where do you need to fix? Is it flat or shaped? Two ways that I know of is, fabricate a new bit of metal that is the size of the hole, and weld it in, or if they are pretty small, just "weld" in the hole... start from the edge, weld against the edge, let it cool, weld against new edge etc keep going till its gone.... 
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| Author: | superSeven [ Mon Oct 27, 2008 11:58 am ] |
| Post subject: | |
what i did on the windows of my old clubby was put a crease or a lip in where the overlap is... so the insert piece from the side would look like this: ___--------------------------------------------------_____ otherwise if you weld a flat piece in, just build up the gap with filler.. 
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| Author: | Wombat [ Mon Oct 27, 2008 2:01 pm ] |
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superSeven wrote: what i did on the windows of my old clubby was put a crease or a lip in where the overlap is... so the insert piece from the side would look like this:
___--------------------------------------------------_____ otherwise if you weld a flat piece in, just build up the gap with filler.. There is a tool that will do that for you. Have seen them on eBay - don't know what it's called |
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| Author: | drmini in aust [ Mon Oct 27, 2008 2:54 pm ] |
| Post subject: | |
I just welded 2 bits of flat in (one horizontal, then another vertical) and ground it flush- no filler.
After it was all finish welded I brushed lots of Coldgal paint up in underneath... it won't rot out there again in a hurry. |
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| Author: | 1310/71 [ Mon Oct 27, 2008 3:06 pm ] |
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Wombat wrote: superSeven wrote: what i did on the windows of my old clubby was put a crease or a lip in where the overlap is... so the insert piece from the side would look like this: ___--------------------------------------------------_____ otherwise if you weld a flat piece in, just build up the gap with filler.. There is a tool that will do that for you. Have seen them on eBay - don't know what it's called I think it is called a flange tool. I've got a compressed air driven one I've never used (the panelbeater who ended up doing my car butt welded it - mostly by spot-weld then infilling with braising; ie a combination of MIG and Oxy acetylene welding). KB |
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| Author: | Wombat [ Mon Oct 27, 2008 4:23 pm ] |
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Following from the Doc's point I had imagined that if faced with that sort of task I would cut a piece to just fit inside the hole and hold it in place with welding magnets and do as the Doc did. |
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| Author: | justincase42 [ Mon Oct 27, 2008 5:26 pm ] |
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The tool used is called a joddler, you can get hydralic ones hich cost around $5000. You can buy ones that are run by compresed air. Mine cost me about $350 from memory and works great. Also comes with a hole punch so you can plug weld panels together |
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| Author: | miniclubbhoy [ Mon Oct 27, 2008 10:14 pm ] |
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justincase42 wrote: The tool used is called a joddler, you can get hydralic ones hich cost around $5000. You can buy ones that are run by compresed air. Mine cost me about $350 from memory and works great. Also comes with a hole punch so you can plug weld panels together
Not taking the P**s or anything, but $5000???? You can buy a hand one for about 40GBP - so I suppose that would be around $100? They do the job well enough if you've got the patience to do it. I've got one sitting in me garage. Not sure where you would buy one here though! If it's a small bit of metal a joddler won't be of any use. If it's a small hole and you want to weld it up like Trixitrine says, that's ok, but be careful that you don't burn a bigger hole (because the metal will be very thin around that area!). |
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| Author: | Wombat [ Mon Oct 27, 2008 10:38 pm ] |
| Post subject: | |
There's a few on eBay mostly from the States but this 2 in 1 Flange tool is local (Victoria) |
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| Author: | miniclubbhoy [ Tue Oct 28, 2008 2:13 pm ] |
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Wombat wrote: There's a few on eBay mostly from the States but this 2 in 1 Flange tool is local (Victoria)
That's pretty good value I reckon! If I had a lot of metalwork to do it would be worth it. |
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| Author: | M-JAY [ Tue Oct 28, 2008 8:46 pm ] |
| Post subject: | |
I've done a few minis now and there are a few ways of doing it, everyone has there own way though. Personally if its a small hole just fill it up with weld. If the hole is too big for this I drop the grinder in with a cutting disk on and cut out a square or rectangular( cos its easier too make plates these shapes). You then get a piece of card and make a template, then you can do it 1 of 2 ways; cut a piece of metal the same size as the hole and weld it in or cut 4 strips of metal about an inch (25mm) wide and spot weld them all the way round on the underside of the hole so half of the width is visable inside the hole.You have now created a ledge for your new plate to sit on just weld in the new metal as per normal. Just remember to paint EVERYTHING with something like a zinc rich primer. Cheapest place for these is an industrial fastner place, spray cans here in SA cost well under $10. I use zinc rich primer as its the same as weld through primer but costs a fraction of the price. The second way I described is probably easier if your a novice welder/bodyworker because you have a piece of metal to weld into underneath. Hope this helps and I've explained it ok |
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| Author: | IwannaMini [ Wed Oct 29, 2008 8:00 am ] |
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thanks for the advice guys... Sorry I am bad at explaining things.... 
Its actually a panel van rear window that had rust cut out.... the side started like this... _______________________________________ but its now something like this _________________________ \______________ if that makes sense... I need to extend the end part on the right upwards so then the rubber will keep the window in... Will the above methods work still...??? Would it be easier to put solid sides back onto the van? |
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| Author: | Blokeinamoke [ Wed Oct 29, 2008 9:24 am ] |
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I just hammer the flange into the panel by hitting over a former I have that is the exact shape - a bit cheaper than $5000 
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