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Tips

Repair panels

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This is a repeat from an older post with some pictures of dogleg panel repair done while leaving the original edge bead. Gas welding was done with a Henrob torch.
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The new patches were created from one piece that was cut and folded to match the original. On both repairs the original wheel arch bead was retained. On the first picture the pillar flange is part of the new patch (can't see it from this view but the metal bends around 90 degrees). On the second picture the original pillar flange was retained because it was undamaged. On both repairs the bottom flange was part of the new patch as you can see. I have highlighted the welded in panels in light red and placed the old panels (P.O.'s hack repair)next to the fenders so you can see the cut lines. Of course the front panel surface has curvature which was formed with a planish hammer (looks similar to an english wheel but has an air powered hammer on the top side and dies/dollies on the other)

dogleg1.jpg
dogleg2.jpg
 
Thanks everone-A lot of stuff here to digest. I'm using a 75/25 mix and pulling the weld. I can lay down a pretty decent bead on a flat piece of sheet metel but when I weld on the car I tend to get burn through. Another problem I have is with visabiliy and keeping on the joint. I try to use a back step method. I pull the weld about 1/2 inch and then back step and weld weld another 1/2 inch and so on. Maybe its just a matter of pratice. I'm afraid if I blow a hole in the original metal after I've cut the panel to fit, I'm screwed.
 
Glad to hear you have gas. (Probably the only time you’ll here someone say that!) A couple of things to consider. Maybe you could use a different shade on your helmet. I have an auto-darkening helmet that can be adjusted from 9 to 13. For MIG I use 11, TIG I found worked better with a 10. I’ve also seen corrective lenses. Some of the guys in our special effects shop need them because they’re far sighted. Another thought is to set up a bright work light so you can see more than just the arc. Vertical welding is tougher. Lay a bunch of tack welds on the panel so it’s secure. Then remove the panel and do your final welding on a bench where the piece is horizontal and you can be more comfortable. FYI I use .023 wire for thin metal.
 
The brighter light sounds like a good idea,why didn't I think of that?I have an auto darkening helment. So far the welding I have done is on the chasis and I have it on a rotessery and can get in any position.
 
Turn down the heat on the machine and try a little higher wire feed rate. My Miller mig can weld some pretty thin stuff without burning through. I`m sure with a little practice you can do it. Skip
 
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