Point of no Return

[david85]

Looking good Justin! Though I do sort of agree that replacing a bed side would have been a lot easier.

When I did the second cab corner on my F150, I spent about a week just fitting it for the butt joint. Then I used a TiG welder to Blend weld it together - that also took a long time. Since I was dealing with sealed, double wall construction, there was no chance of getting behind the panel to bash out any warpage so I figured it was time well spent. Literally one little touch of the flame, drag the puddle across the joint, then let it cool (repeat a few hundred times and it was done). In the end it had some tension, but at most I used 1/16" of filler on it so I was happy.

The first side was with a shielding gas Mig Welder. That worked ok too but not as clean. Although with Tig, any gap was not possible without ruining the whole job (that might be why I haven't heard of many using it for body work like this).

 

[cornbinder 84]

Since your are using flux core wire make sure you get the weld ground down and cleaned good. I have seen a weld made with a flux core welder show in the body work after a year or so. Usually it is where the flux and slag is left in a pin hole in the weld. I don't if there is a chemical reaction with the bondo or what but, it will make a bubble in the paint. You shouldn't have any problem as long as you get everything good and clean.

 

[redneckaggie]

with Tig, any gap was not possible without ruining the whole job (that might be why I haven't heard of many using it for body work like this).

with tig welding any gap should be possible because you control how much weld metal is put in with one hand and heat with the other

the main reason it is not used is because it is very time consuming and tends to pull more when tacking

 

[david85]

with tig welding any gap should be possible because you control how much weld metal is put in with one hand and heat with the other

the main reason it is not used is because it is very time consuming and tends to pull more when tacking

While I don't disagree, I found that Tig welding sheet with a gap would result in way too much heat going into the parent material and made warping MUCH worse than with Mig under identical situations. However if there was effectively zero gap and I could blend weld, (no filler at all) the heat added to the material (and subsiquent warpage) was much lower than Mig, under the same conditions.

 

[FordGuy100]

It is difficult. First time with flux core, first time welding sheetmetal, first time having to deal with warpage, etc. I think I'm doing alright though

 

[Diesel_brad]

TIG welding gets WAY to hot for sheet metal repairs, that is why you don't hear about it used. Mig is the only welder to use. And if not a structural repair, panel adhesive is the cat ass

 

[gunz]

While I don't disagree, I found that Tig welding sheet with a gap would result in way too much heat going into the parent material and made warping MUCH worse than with Mig under identical situations. However if there was effectively zero gap and I could blend weld, (no filler at all) the heat added to the material (and subsiquent warpage) was much lower than Mig, under the same conditions.

Thought I would chime in here. Tig and filling the gap is very easy and very possible if you use the remote and drop the heat off as soon as you start to see any sign of the puddle , then you add the rod and carry the flame . Repeat.

 

[david85]

TIG welding gets WAY to hot for sheet metal repairs, that is why you don't hear about it used. Mig is the only welder to use. And if not a structural repair, panel adhesive is the cat ass

Again, I don't disagree in principle, but in my case, there was less heat due to the type of prep work I put in ahead of time.

 

[gunz]

Again, I don't disagree in principle, but in my case, there was less heat due to the type of prep work I put in ahead of time.

Another point not discussed , is which welding you are morre familiar with. If you tig oftern and are familiar with your machine it will work fine. Same can be said for Mig.


I am the avaiation welder on the base so I am usually behind a tig torch several tiems a week. I do get soem good time on the Mig as well, so i stay pretty current. My point is if you are more familiar /comfortable with one process over the other, then go with it. Keep in mind the thickness of the metal your welding and make short tacks then short welds, it should work out fine.

 

[RLDSL]

Since your are using flux core wire make sure you get the weld ground down and cleaned good. I have seen a weld made with a flux core welder show in the body work after a year or so. Usually it is where the flux and slag is left in a pin hole in the weld. I don't if there is a chemical reaction with the bondo or what but, it will make a bubble in the paint. You shouldn't have any problem as long as you get everything good and clean.

As long as you hit it with metal prep , no worries, otherwise it will rust through

 

[94f450sd]

looks good.i would not use a flux core on a body panel.flux core just plain sux.

as far as piecing it VS replacing the whole side.i woulda done it the same way.

panel crimpers are nice but then you end up with a lip on the backside that will collect water and crap and start to rot.ya you can weld the backside or seam seal it but there are places that you cant get at with either.plus the crimper itself can warp the panel.

i prefer to butt weld.and i know many body men that prefer to butt weld panels.its not that hard once you learn how to do it.less warpage and less filler.

 

[RLDSL]

Yeah flux core can be pretty sloppy....I don't even bother using it anymore for that reason! 100% argon is my choice. When it was opened up, were you able to see around the inner part of the wheel arch? I often wonder how much area there is available for crap to gather and rot out the box....wonder if spraying undercoating in would help? Anyways looking good!

Is there some reason that you'd be using straight argon on a mig with steel instead of a mix? It doesn't penetrate as well. ( oh to be able to only have to keep just one bottle laying around )

 

[94f450sd]

Is there some reason that you'd be using straight argon on a mig with steel instead of a mix? It doesn't penetrate as well. ( oh to be able to only have to keep just one bottle laying around )

i run an argon co2 mix.i only have one bottle.IIRC its 75% argon 25% CO2

 

[Diesel_brad]

Straight argon is for welding aluminum

 

[papastruck]

How straight was it after it cooled? I did the exact same spot. When the tacks cooled, the crown of the panel flattened out and the thing needed way too much filler to straighten out. I'm running with the wave now, but when I get the chance, I'm pulling it off and doing the whole bedside. Yes, Brad, you told me so.