Van sill repair

[Paulie73]

Hi guys I’ve got to weld some plates into the sills of my van as there’s a bit of rust I need to cut out ! Appreciate a good setting amps/wire speed to make sure I penetrate and not blow through! I’m using flux core gas less as I’m welding outside ?

 

[tom2207]

I always set my machine to

wire speed .... 4
power ,,,,,,,,,,,, 7
radio ,,,,, greatest hits and kettle on

hope that helps
if not you may have to set up a test piece and do some experiments until you get to know your machine .

 

[Paulie73]

I’ve tested on 1mm metal pieces and get quite a good weld on 50 amps and wire speed 4.5 but come time to actually weld on the van sill it never is as good as scrap clean metal

 

[bourbon]

Your sills are not going to be 1mm thick good steel or not. What van is it?

 

[Paulie73]

Ford connect I’m sure what thickness the sills are but I’ve loads of sheet metal which is 1mm

 

[mr haynes]

Just to confuse some more, start at 14.5 volts

 

[tigdlo]

In case you didn't get it, a couple of the previous coments are telling you there is no way of knowing what to set your machine at without trying it. Having said that 14.5v wouldn't be a bad starting point, if you can set your welder to 14.5v. With more information someone will be able to give you a starting point which you will have to try on practice material and make adjustments to get right. These setting will then likely be wrong for welding new 1mm to rusty sills so you will have to adjust again when you get to welding on your van.

What welder and wire do you have? What settings does it have? If you are unsure post some photos.

 

[Paulie73]

I’m using 0.8 flux wire and I’ve got inverta digital 200A draper mig gas / gas less welder which I’ve been impressed with ! I probably start at 35 amps so I don’t blow through, the volts adjust automatically I think as you weld

 

[tigdlo]

Are you just going to put a ptach over that hole? It's probably best if you cut back at least a couple of inches all around the hole you can see and make a patch with a flange, plug weld the flange and seam weld the top and both sides.

check out the tutorial and techniques here, https://www.mig-welding.co.uk/mig.htm You can post some photos of your practice welds if you need some help setting up.

 

[Windy Miller]

If you’re cutting out all the rot, cut out a slightly larger area than is necessary, and use the non-rusted part to fine tune your settings.

 

[Onthespotwelding]

Ford connect

I’ve loads of sheet metal

You're gonna need it ford's love to rust.

Cut the rot out, DO NOT just plate over it.

 

[Paulie73]

Yes I’ve only grinded some to see the extent of what’s to be done ! I’m gonna be cutting all rot out and but welding a patch in so it doesn’t notice after the work has been done

 

[Paulie73]

Yeah fords do like rust my Vw is better lol I’m not gonna plate over it as cutting all rot out

 

[Pigeon_Droppings2]

cut out a slightly larger area than is necessary, and use the non-rusted part to fine tune your settings.

+1 for this...it's exactly what I usually do.

 

[Paulie73]

Got to cut this mess out also and make a plate to but welding it up nicely

 

[pedrobedro]

Hit it with a hammer till it stops flaking and starts bending then sweep up and start cutting. Weld on your 1mm plate edge and lap it onto the thin stuff.

 

[Morris]

Hit it with a hammer till it stops flaking and starts bending then sweep up and start cutting. Weld on your 1mm plate edge and lap it onto the thin stuff.

This is incorrect. It's a Ford, cut through the roof pillars and replace from there down.
No need to thank me.

 

[Paulie73]

And more I just have to keep going along both sills till the rust stops

 

[tom2207]

keep cleaning back with a scotch brite disc o the likes until you have a clean silver edge all the way round ,,,, you cant start a repair until you have an edge to work to ... you need an edge so you know where to stop .

 

[Paulie73]

Yeah will do once I get to clean metal I cut the rust out template it onto new metal and butt weld he new sheet in hopefully