Cutting filler from base ali sheet

[minimutly]

I've picked up the making "new sidepanels for my xj650" job again. I made one earlier this year, using 3mm sheet I had left over, with mounting points turned like the originals or flat "ears" with slotted holes to go over the rubber bobbins in the frame. The technique being to drill or slot through roughly the right spot in the side-panel, fit, then quick tack in place, remove and weld up on the outside, file and polish back.
Trouble was, this left a slight colour blemish in the polished surface. So yesterday I cut a sliver off the original sheet to try this as filler. Initial tests showed promise, with clean, shiny weld. Is there a downside? I recall cracking being an issue - due to lack of silicone?

 

[TechnicAl]

what grade is it

 

[minimutly]

Really, I have no idea, it's general purpose fabricating ali sheet, fairly soft to work, welds nicely.

 

[TechnicAl]

Difficult to say then............Make sure its really clean and give it a go....it can only crack and then you will know you need to buy some

 

[Shox Dr]

Really, I have no idea, it's general purpose fabricating ali sheet, fairly soft to work, welds nicely.

1005 or 1050. I forget the rod to use. Think its a 5xxx series

 

[minimutly]

1005 or 1050. I forget the rod to use. Think its a 5xxx series

Yes but you missed the point in my query - I want to avoid a colour cast.

 

[Shox Dr]

Yes but you missed the point in my query - I want to avoid a colour cast.

I thought the weld was showing. Search for ‘hotrodder’ s posts, he explained it far better than I ever will

 

[TechnicAl]

If it is 1050 cutting a sliver will be ok....it should weld fine

 

[Brad93]

If the sheet is 1050 then a strip of sheet will work perfect as filler.

If you don’t know the composition of the sheet, then use a properly alloyed filler metal or you could end up with cracking issues.

 

[minimutly]

If the sheet is 1050 then a strip of sheet will work perfect as filler.

If you don’t know the composition of the sheet, then use a properly alloyed filler metal or you could end up with cracking issues.

Well, cracking is not the end of the world, it's not structural, and if it cracks it means I'll have to use filler rod to repair, resurface and then either live with the colour mismatch or paint them both.

 

[Brad93]

Well, cracking is not the end of the world, it's not structural, and if it cracks it means I'll have to use filler rod to repair, resurface and then either live with the colour mismatch or paint them both.

Just use a 5356 or 4043 rod

 

[minimutly]

Just use a 5356 or 4043 rod

Are you saying these rods won't give me a colour cast?

 

[Brad93]

Are you saying these rods won't give me a colour cast?

You’ll always get a different colour. Even if you use a piece of 1050 on 1050 you can get a different colour

 

[minimutly]

You’ll always get a different colour. Even if you use a piece of 1050 on 1050 you can get a different colour

Now that's news to me - thanks

 

[Brad93]

Now that's news to me - thanks

Some elements don’t transfer across the arc as well, you also form an ‘as wrought’ material where you have welded which is a completely different grain structure to the patent metal and hence there can be a colour difference.

Another reason for welding aluminium panels with oxy acetylene.

 

[Brad93]

Gene Mathers pretty much wrote the textbook on aluminium welding. It’s available on the web as a PDF.

 

[minimutly]

All welded up,will post pictures tomorrow, the sliver welded ones have much less, but not zero colour colour cast.
In fitting these sidepanels I had to "fit" the rear edges of the maxim tank. Lo, the 39yr old tank sprung a couple of leaks, right at the back lower corner on one side. I cleaned it out inside (its never been sealed), and soldered up both areas with soft solder. So the question is - will this hold or do I need to seal it as well?

 

[minimutly]

All welded up,will post pictures tomorrow, the sliver welded ones have much less, but not zero colour colour cast.
In fitting these sidepanels I had to "fit" the rear edges of the maxim tank. Lo, the 39yr old tank sprung a couple of leaks, right at the back lower corner on one side. I cleaned it out inside (its never been sealed), and soldered up both areas with soft solder. So the question is - will this hold or do I need to seal it as well?