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Hi all,
I am replacing the lower part of the outer sills on my TR4A. I bought new sills from TRF. Using a contour gauge I marked a line on the old and on the new, and cut the parts to match.
I then butt-welded the new piece in place. And it looks fantastic, except...
When I grind down the weld to be flush with the metal, some areas have a crack in the joint. I have been grinding very carefully not to grind the surrounding metal, using an air die grinder plus a 36 (?) grit sanding disk. In parts I use a cut-off wheel and carefully hit the top of the weld.
What did I do wrong? I'm thinking either I did not get sufficient penetration of the weld through the metal, or the welded joint is brittle and I have cracket it during grinding, or ...?
I have access to the back of the sill and will weld the joint from the back if needed. But then I will have a bunch of "pockets" along the welded joint for water to collect on... I'm open to suggestions.
TD Skip is carrying out a similar repair on the Triumph forum; https://www.britishcarforum.com/bcforum/ubbthreads.php/topics/563439#Post563439
I am replacing the lower part of the outer sills on my TR4A. I bought new sills from TRF. Using a contour gauge I marked a line on the old and on the new, and cut the parts to match.
I then butt-welded the new piece in place. And it looks fantastic, except...
When I grind down the weld to be flush with the metal, some areas have a crack in the joint. I have been grinding very carefully not to grind the surrounding metal, using an air die grinder plus a 36 (?) grit sanding disk. In parts I use a cut-off wheel and carefully hit the top of the weld.
What did I do wrong? I'm thinking either I did not get sufficient penetration of the weld through the metal, or the welded joint is brittle and I have cracket it during grinding, or ...?
I have access to the back of the sill and will weld the joint from the back if needed. But then I will have a bunch of "pockets" along the welded joint for water to collect on... I'm open to suggestions.
TD Skip is carrying out a similar repair on the Triumph forum; https://www.britishcarforum.com/bcforum/ubbthreads.php/topics/563439#Post563439