Welding smooth

[dadangerman]

Hi there I'm welding my engine bay on my mk2 smooth.
So i am welding all the wholes and filling smooth.
Whats the best method of doing the welding?
I have been trying to make plates that just fit flush and butt welding them. But i am blowing through a lot as my patches aren't perfect size. Would i be able to plate a cut a piece that is bigger than whole,hold it against hole and weld that way?
Also what are the best tools for cutting nice patches out. Ive been using shears i found but they are a ball ache.
Thanks in advance

 

[awemawson]

Are you sure that you've got whole holes, or are your holes wholly or partially missing

Andrew

 

[mike 109444]

Smoothing...... Each to there own
Assuming most of the holes are round, guessing 3/4" to 11/2" then first make sure you are marking out the circle using a set of dividers or compass. Then cut using a good pair of tin snips close to the line. Now file remaining amount to the line and BEFORE trying the piece in the hole tack to the middle a strip aprox 1/4" wide by 2 or 3" long. Now when you try it in the hole if it fits well it will probable fall through ! hence the strip !! The strip will also allow you to hold the patch while welding in. If you allow the patch to sit just below the surface this will give somewhere for a smear of filler to go. The same applies for any other shapes you may have to put in.
If you have an engineering company near you that does panel punching (preferable with cnc, they would advertise this!) try popping in and explain what it is you are doing, then following the strange looks, ask if they might have a handfull of mild steel punchings from there cnc that you could have a rummage through

 

[mike 109444]

Ps MK2 what ???

 

[chevy2]

A 1mm cutting disc in the grinder generally makes neat cuts without distirting the edges,
If you're not bothered what the back looks like then make oversize patches and fit from the back,
Problem is that the repairs take a lot of filler which is likely to sink or crack when painted,

Best option is to spend a bit more time making well fitting patches and weld them in flush as they'll need less finishing before paint,
dont rush the welding either, especially on the flat areas or it'll distort plenty,
Small tacks and allow to cool between each one, you can also quench it a bit with a damp rag to keep the sheet steel tight and not warping,
Sounds a lot of extra work but it'll save a lot of prep before painting.

 

[bc30se]

hmmm, not sure if you get him right...

what he is trying to do (I suppose) is to make his engine bay clean, and I am pretty sure he is referring to vw golf 2

 

[chevy2]

hmmm, not sure if you get him right...

what he is trying to do (I suppose) is to make his engine bay clean, and I am pretty sure he is referring to vw golf 2

Thats what i guessed he was trying to achieve^^^

 

[bc30se]

This, however, wasn't done using fill patches, just spray filler, sand it smooth and paint...

I wouldn't suggest doing any patching, rust will eventually come out of the welds as you will create an air pocket bewteen two metal sheets.... (as I understand correctly)

PS
Personally, I hate the 'clean look', but if you go for it, try to watch this, a guy found a good way to do it in his car....

 

[dadangerman]

Sorry for the terrible explanation etc, yes the above is what I'm going for.
Ive been using a cut off tool to do any long cutting that would be a ball ache with shears.
Can someone send me a link to a decent set of tin snips?
Also I'm using a murex 245 tradesmig. I do have a Clarke 100en but the tensioner broke so wire feed isn't consistent.
I will cut a load of lines on a spare wing i have and try to adjust welder settings. When doing body work do you want slow or fast wire speed

 

[zardoz]

if you want to make precise cuts, a pair of snips can be used but you need hands like Conan. I would cut it in to rough shape with either snips or a small grinder with a 1mm (or less) disc, then grind it in to its final size and shape. I have done it this way myself.

Otherwise it'll have to be a Plasma cutter.

You want slow wire speed. As a higher speed will automatically pump more amps through the wire.

 

[Fastfingaz]

Would a holesaw work? it fits on to your drill motor and it cuts various sizes in lite metal ,,, like from 1'' to 3''

 

[jinjahbiscuit]

The problem with a hole saw is the pilot drill makes a hole in the disc you're going to use for your patch. So you end up with another, albeit smaller one, hole to fill in.

 

[bc30se]

Now let me show you something. Recently, I laser cut a battery cover, and also needed to be almost as precise as you. What I did was.... I made a paper template to fit the space as I wanted it, next I drew it in autocad and finally send to the company to have it cut... I think you could go this way also... just to show my work..

Now, the problem is... I didn't want it clean, but anyway what I think is that it looks quite overestored.. after some time I believe.. not a good way to go....

luck with your cleaning though

 

[normspanners]

Ps MK2 what ???

There is only one----- REAL mans MK2 and thats the ESCORT any of the others have just copied the name

Ive been using shears i found but they are a ball ache.

gilbo's are a ball ache especially when the tin twists and they lock down on your right testicle, I learnt very early on not to use your thigh to push down on to get extra purchase to cut some extra thick tin!!

 

[Sean]

Sharp scribe and a slightly worn 80grit flap wheel to buff the patch down to your scribe line. Then a copper chill bar to avoid blow through.

 

[lshigham]

My technique is to hold a slightly oversized peice of metal to the rear, draw round the inside of the patch with a marker, cut to the line with aviation snips and weld it in

 

[Sean]

My technique is to hold a slightly oversized peice of metal to the rear, draw round the inside of the patch with a marker, cut to the line with aviation snips and weld it in

yup but i use the scribe
All this "Smooth" make the cars look like an Airfix kit

 

[Wallace]

A Tradesmig 245 might be a bit hot on it's lowest setting for thin sheet but it is doable by keeping heat in the work down. The 'copper chill bar' Sean mentions is really good but I suspect most of what you are trying to patch is on odd shape inner wings and bulkheads so it's not easy to get a heatsink in. Very short welds or tacks cooled with compressed air works well once you get used to it. Some useful tips on using aviation snips here that can be applied to other types of shears, might save you wasting money on tools by using a different methods.

 

[dadangerman]

Hi all thanks all for the quick responses. I've sorted the problem with my welding bunching up. and have lowered the wire feed speed down. with my welding I am doing overlapping dots rather than keep it going as it burns through unless i can get to the other side of it, then i have my mate hold an alloy bar on back end. and now cutting my patches I use another pair of aviation snips and a bench grinder.
I could do with getting some lessons to help me get my welds looking good.