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A pillar replacement

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Ray,

About 3-4 years ago I took the easy way out and used one of those metal patches and bondo on both sides. Lasted a couple of years but that cheap fix does not last. When I had access in there all looked pretty good other than the outer skin. This car had outer sills replaced by P.O. when I bought 6 years ago and it had been sitting in a garage for a long time. Did not notice rust coming back until about a year ago when Bugsy lost his indoor storage. Indoor storage definitely retards rust no simply slows down rust. Floors on this car were totally rust free and inner fenders look good. I did use some of that rust encapsulation/conversion stuff when I had access inside the outer skin. I'll give a complete report once I get it back in the garage and holiday honey do jobs are over with.

I do have a concern as I have a crack in the lower hinge that needs to be repaired. The curse of the no door check strap when I bought the car for a few months. Hoping there is room to get in there and weld easily rather than replacing the tapping plate.

All speculation at this point as Bugsy sitting outside under his car cover. Need to get him back inside before the white stuff happens and he gets buried. Better half has given tentative permission on acquiring slightly used MIG Welder. My Christmas present to myself.
 
That would be great, Jim, if all that is needed is the skin...an easy repair.

If it's the hinge itself that is cracked, then I'd take it out and to the bench for cleaning and welding. Your MIG gun will be able to get into some small places, but the trick is getting it clean enough for a clean weld.

Congrats on the welder...don't know how I would have gotten my project this far without one. If you're new to welding, run by a welding shop and buy (they'll probably give them to you) some off-cuts of practicing. Be sure to get various gauges. If that's not doable, some of the home builders mega-stores (Lowes in my area) carry some steel sheets and structural shapes in various sizes (designer sizes...de$igner prices). If they are too clean, wire brush them and lay them outside for a while. You want to get your rust removal, cleaning, welding down pat before you do it for real.

Ray
 
Great thought, prerust the metal to simulate what I'll be getting into. Thanks Ray.
 
Go to a U - pull junk yard and ask them for some crumpled/rusted out fenders and hoods to practice on. Shouldn't cost more than 5-10 dollars.

I bought my welder from a welding distributor that had a used model that had been on a year long loan to a local high school shop class. It looked almost like new.
 
There is a major Welding Shop Distributor here in Dayton. I need to run down on a Saturday and see if I can make any kind of deal. Found a cheap MIG that has been supposedly gently used for a few months. $150 without gas bottle. might or might not be a good deal. Need to look at it this weekend.
 
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