Sheet Metal Gap Filling

[Paul3944]

I need advice before I start (mess up) welding in a replacement outer panel on my van.

I’ve cut the new panel to size and achieved a consistent 1mm gap except for one part probably about 10cm in length where the gap is about 2-3mm.

I’m currently using 0.6mm wire would 0.8mm be better to fill this gap?

Thanks

 

[mike os]

0.6 will be fine

 

[daedalusminos]

Providing you don't tack weld where the gap is too great, you'll find the gaps tend to pull together. I would move that clamp as far away from the wide section, and tack towards the wider section - you'll find your 1mm gap will reduce along with the wider section. You may need a clamp on the wider section to keep the panels flush.

If this shrinking technique is likely to result in too much distortion then you could always lay a slither in the gap.

 

[Dcal]

Can you get at the back?
Placing a backing plate of copper or aluminium (flattened copper pipe will do the job) would make the welding easier, but it should weld fine without it.

 

[Paul3944]

I’ve got a piece of sheet copper about A4 in size. I’ll try and find way of keeping in place while I weld from the outside. I think I’ve got some of them large fishing magnets in a box somewhere.

Good suggestion about moving the clamps. I’ll have another look at this over the weekend.

Thanks

 

[bourbon]

Butt weld clamps. https://stakesys.co.uk/wg120-butt-weld-clamps-4-piece-set

 

[OJCar]

what are those little clamps called?

Intergrips

https://www.mig-welding.co.uk/forum/threads/intergrips.76763/

where can i get clamps like this?

http://i27.photobucket.com/albums/c190/procharged79/roofrepair003.jpg look quality, possibly home made, im not sure.

www.mig-welding.co.uk

Some on e-bay

 

[Dcal]

I’ve got a piece of sheet copper about A4 in size. I’ll try and find way of keeping in place while I weld from the outside. I think I’ve got some of them large fishing magnets in a box somewhere.

Good suggestion about moving the clamps. I’ll have another look at this over the weekend.

Thanks

I've used a bit of tying wire to hold a backing strap in place when I can’t get at the back.

https://www.mig-welding.co.uk/forum/attachments/img_3198-jpg.142812/

 

[Paul3944]

I've used a bit of tying wire to hold a backing strap in place when I can’t get at the back.

https://www.mig-welding.co.uk/forum/attachments/img_3198-jpg.142812/

What a great idea. Thank you

 

[T5 TDI]

Just done that job on my van. Plenty of good advice to be had here. I learnt loads. Needs to cleaned right back to bright metal using a poly disc (which doesn't thin the metal) If you do have to weld outside, pick a still day especially if you are using gas. Tack first all round and confirm no movement, then don't go for any long runs on that thin metal (however well it's going!) Use a auto darkening mask and use both hands. Practice loads on scrap before going near the van..