Gaps in welding

[amazighman]

Hi guys.

I am new to the welding scene, I have been practising on some 1mm steel and the results were good...I managed to get the settings all OK for a begginer and the welds were good and penetration fair.

I tried to weld a patch in my Mercedes CLK 430 spare wheel well... And the results weren't so good like with sheet metal... I am thinking the repair patch I made had gaps here and there and it wasn't good fit....
After good bringing holes and gaps started to appear.... Please see the picture...

Please advice me guys....surely I am doing smth wrong....should I try to weld over this patch again? Weld underneath it? Or cut it out an start all over again?

Thank you

Many thanks

 

[123hotchef]

pics too dark and too far away

 

[roofman]

Hi guys.

I am new to the welding scene, I have been practising on some 1mm steel and the results were good...I managed to get the settings all OK for a begginer and the welds were good and penetration fair.

I tried to weld a patch in my Mercedes CLK 430 spare wheel well... And the results weren't so good like with sheet metal... I am thinking the repair patch I made had gaps here and there and it wasn't good fit....
After good bringing holes and gaps started to appear.... Please see the picture...

Please advice me guys....surely I am doing smth wrong....should I try to weld over this patch again? Weld underneath it? Or cut it out an start all over again?

Thank you

Many thanks

Try to get the sides of the hole straighter and square then use carboard as a template for your patch...a patch that fits IN looks far better than one that goes OVER iff you get my meaning and a tight fitting patch takes the heat a lot better on both sides of the repair...after putting it in the hole then hold it with magnets and tack the 4 corners and 4 sides then start welding by putting more heat into the thicker metal 1st which i should think would be your patch,dont try to seam weld it in a single run but more of hopping from side to side with spot welds so you stop the risk of too much heat and blowing holes...after its fully welded then get the grinder in there and flatten down.

 

[Kent]

Can't really see but I suspect like most you jumped straight from an hours practice to a far higher degree of difficulty. Positional. Cramped poor light and old materials
Happens a lot.

 

[amazighman]

I guess i have to cut it out and weld again.It is quite awkward area to cut with an angle grinder in the boot...I bought an air cutoff tool but the disc is quite thick 1.6 mm...hope there is way thinner...

I tried 30amp and low wire feed and I don't get good penetration, even though 1mm steel has to be welded with lowest settings and wire speed..

 

[Kent]

It's impossible to say- is it a mad rush? The plate looks a little small that's all I can see. Generally on your first rusty car you think of the little hole not necessarily the soundness of all the surrounding metal.
This often leads to the patchwork quilt effect I have been there many years ago and learnt to be a pessimist instead of an optimist with a hammer and old Screwdriver

 

[amazighman]

Sorry for the bad pictures....
The boot floor is sound....around the patches is shiny metal...I cut about 1inch after the rusty metal ends to make sure no rust is left....before I welded I made sure the metal is clean and shiny and the repair patch clean.
I have to agree with you Kent....I didn't have adequate light when welding... And the patch was not a good fit..

I have to invest in poper light torch..and fabricate a proper fitting patch.
Trial ,error,advice,success, that how I learned many things...I am determined to learn welding and I will ursue that

 

[amazighman]

I will do more practice too. And then when happy I will cut out and weld from new..hopefully my argon co2 10l will last a bit longer

Thank you for help and advice guys.

 

[Kent]

It might take you a great deal longer than an Experianced hand but with the correct attitude you will at least Learn with each job!

Honestly on all the fails I have seen on here most are because of jumping on a real job too quickly. Its a lot different when you have awkward spots and angles of travel. Inclines curves etc etc

 

[amazighman]

Hello guys..
I went and cut out the old welded patch, I tried my best to make the cut a simple shape..
Tacked in place...used hammer to make it fit where necessary. And then welded it...
It could be that my wire setting was a little too high as I got quite rised welds....but for newbie I am quite happy..
Needs grinding but it is awkward to get an angle grinder in the spare wheel well.... So I am leaving it like this....there is a little hole on the left which I forgot to weld I guess I ll just paint it and leave it...

Thank you for help and support... Your advice is highly appreciated.

 

[123hotchef]

weld the hole or it will get wet inside and rust looks ok for a newbee

 

[amazighman]

I think you are right.I better weld it....

 

[123hotchef]

shame to go to all that effort and have a wee hole

 

[amazighman]

I only have a wolf hobby MIG..I don't think that is helping....
My wire is 0.6mm and argon co2 gas...I tried o 1mm sheet using 2nd setting amp and 4th wire speed and seems very good....
Trying that on the car it does blow holes so I think car wheel well is 0.8mm steel
I reduced amps to minimum and wire feed to position4...and I managed to weld it following the thin steel method.. As I said I guess my wire feed was a bit too generous
Still got a lot to learn

 

[123hotchef]

you and me both mate we are all students in the university of life