OLD RUSTY SHEET METAL Weld Repairs
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- เผยแพร่เมื่อ 2 เม.ย. 2020
- #welddotcom
We are still working through your requests that were submitted through our Instagram story. @bostonrush77 asked us to show how to do old rusty sheet metal weld repairs, so here it is! We are going to show you how to weld sheet metal that is rusted out and in bad shape. This is very common in the welding restoration of old cars and tractors. Today's weld project is a 1949 International Farmall Cub.
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This has to be possibly one of the most important videos of ALL the welding videos available. From start to end with all of the fine details. Many thanks. Always a treat.
Nice job young man! Love the way you tell us your mistakes and you let the viewer know that this is not a structural type weld. It's bodywork! Different!
I love this guy. Dumbass me. Lol. I love seeing other ppl forget the little stuff like I do. Great video keep em comeing. Using the down time to learn and increase my skills
Lol..thanks Keith
Every trip down a road has a rock on the path...
Just saying....
For the guys working sheetmetal. 13:29. You see that gap open up on the front? That is a bit of a compound curve. His template was not pressed against all surfaces at the same time when he was marking it. This is expected. Depending on the curves and your experience you may want to add 1/8" to 1/4" of material to your patch. Then take the time to form the patch to match all curvatures. Once satisfied with the curves trim it back to size. Like everything preparation is where it is at. When possible I use a copper backup to act as a heat sync, and to keep some tension on long flat areas. Helps keep them from sinking. Don't forget you can weld it from the back as well. I highly recommend a quality seam sealer on the back. Jumping around making spot welds almost guarantees some pinholes. All it takes is one to wreck the repair in a few years.
He didn't bend the whole patch down at the same time, just the corner. Naturally it'll get shorter when you bend the corner down and in.
@@danjennings5068 Well you can't bend anything at the same time, even when die forming. Always leave extra material. Form the shape first then trim the excess.
This is really the most informative patch video I've seen. You talk about gauge, what it means, how to measure it, bridging big gaps, wire size, putting copper below to dissipate heat and not burn thru...even showed s*it happens. Just information packed. I watched twice and found stuff I missed the first time Keep up the detailed tips . You made it look easy, and it is not. Thank you. Wish I was young again to do this kind of stuff
Thanks you Sir. Really appreciate it. Stay healthy. Thanks
@@mancubwelder1312 You show feed, voltage, gas, and wire but I didn't hear you mention the amperage, did I miss anything? Thanks!
@@RagingShrimp67 when MIG welding I think you only use gas, voltage and wire speed don't think you can adjust amperage.
Not to mention starting your tacks off a previous tack as its thicker material... duh but never thought of it! Haha awesome stuff
@@RagingShrimp67 the amps are linked to the wire feed rate
Nice job cub..
Waited a long time for something like this. 1/8” and up is easy to weld. Gauge metal is a different story.
Yeah, ive been practicing with 14ga and 1/16" stick, the tinyest gap will blow thru in a microsecond. But its too much fun.
Learn on thick stuff first, get a feel for welding THEN go try sheet metal. Will save a ton of frustration.
1/8" is 11ga. 🤯
scott L I found that out the hard way, by doing the exact opposite. Blew a hole, tried to fix it, blew a bigger hole, threw welding machine through the window, told wife, she made me go out and pick up the welder. Ok, I didn’t throw it out of the window, but I definitely felt like it.
Mark Harris that’s exactly the mistake I did too when first welding. Blew tons of holes got super mad. Had a welder buddy come over and got me welding in a hour MIG welding on THICK material! Trying to help others out to prevent what you and I did!
Down to earth guy, I've been welding anything and everything for years, only way to learn in the real world is trial and error, best advice I can give is prep work pays off.
Pure Magic
I never get tired of seeing a skilled person pull together fairly simple techniques, and tools from their big bag of tricks and creating magic. It is the very essence of what makes us human.
Also, from the more than a few of us who have at least pretended to weld sheet metal,
respect!
Great video thanks 👍👍
First ever panel I welded into a vehicle was the rear arch of a VW T4 camper van. I tacked it into place as a normal person would, but then it took a turn for the worse. I strung a continuous bead all the way round it... none stop,.. about a meter long bead all the way around a sheet of what was probably 1.5mm thick sheet steel, butt jointed right around its perimeter to other thin sheet steel, all in one go. I had been told I couldn’t do that, and thought I was being clever by doing it. That was until I realised that the panel had pulled in by about 35mm in places, and the guy telling me I couldn’t do it actually just meant not to do it. I’m not even exaggerating, when I lifted the mask it looked like a stormy sea.
Thanks for the teaching.
Hector thank you.
Man this is just beautiful
I hope Bob Moffatt is back soon, out of quarantine. I love this guy. I really do. I pray, that there are many vids and many good days for him to come! Such a wonderful human being. Greetings from Germany, Marlon
Patience, technique and the right tools does it every time.
You forgot what's most important...skill.
@@Snap_FL right. The S word. Getting scarce in this world where most believe an office job is the way to go.
Most informative video I have found yet. Thanks.
Just about to go out to fix a smoker and this came up. Thanks for the refresher. It'll come in handy.
Thats was both fun and very instructive. Thanks for showing how it's done.
thanks for this educational video
it was cool to leave in the small mistakes and all the meticolous work that is required for good fitment
it was really good to see that even the pros need time for such work and that its not cut precisely to size
Excellent work! You start by tack welding the first round, then you come back a second round then a third, fourth and before you know it you have a weld all around. Thank you for sharing my friend.
Mike, nicely done. Layout, planning, and process. Also, thoroughly enjoy you being a human, and identifying your missteps, and adjusting. Good stuff. Repair work takes a different approach and mind set than fabrication from fresh, new stock. Added bonus, that is a Farmall Cub hood and tank, and I am 100% a Farmall guy! Well played.
Thanks Tom. Trying to change it up a little. Thanks for watching weld.com. stay healthy
Nice work. Enjoyed your explanation on how and why. Thanks for taking the time. Stay safe.
Nice to some old equipment get some well deserved love. Well done!
Very well made video young fella thanks for sharing your knowledge you sound like a young man worth his salt. Good job, from one thats been around since dirt was invented. ✌️
@7:20 i learned a trick of having a can of $.99 black spray paint, and just mist the cardboard so it leaves a shadow you can cut out. the marker sometimes is too thick to get an accurate cut. drawback are fumes, and having to clean it off the metal ( not an issue if done before grinding)
For the arrogant that says that tacking is not welding, they need to look your work. Great job!
very good tutorial,
a very important operation is to cut off the tip of the feed wire so you start with a fresh wire tip.
Forming the patch panel before welding it is a good way to avoid undue reshaping after the weld is completed.
very good video
Thanks for producing content, something "educational" to watch during lockdown
I always love seeing body repairs using new metal and welding, then tons of body fillers. Thumbs Up!
Holding a piece of aluminum behind the weld helps bridging the gap and helps draw away the heat.
Aluminum or copper will work. As long as it’s a dissimilar metal from the base
fit it properly and there won't be any gaps
Nice work! I’m getting ready to tackle some rust rot in the floor of a van that needs some TLC. But I’ll quote what my old foreman told me once years ago in a ornamental iron shop. He said, “you can’t screw up with iron work….you have a welder, a torch, and a grinder. If you screw up, you take those three tools and you fix it.” Probably the smartest man I ever knew…..Leon Welch. I’ll never forget him.
The magnet thing - that kind of thing gets me sometimes too. Spend a couple seconds thinking wtf, then feel like an idiot for a few minutes. 🤣 Thanks for leaving it in 😄
Yeah! Lol.. stay healthy. Thank you for watching weld.com
I work with 18 gauge square tubing to make gates and steel doors and I use the exact same process as you do. At the end, I have a weld all around.
Very well explained. Thank you for sharing your knowledge and skill.
Thanks for this video, with lots of explanation. It's the little details that some videos don't explain and then it bites the viewer when he tries to do the same thing.
Great video. This car body work reminds me of these old welders we got here by Kemppi, back since the 1980s they had a type of primitive pulse function, worked real well on auto body parts as you could use higher amps and the weld nugget would flow out flush real nice, hardly any hammer work required. Or so I was told by the old hands at welding as I was looking at buying one of those old welders.
I have restored a few tractors and kept them out of the scrapyard. This was really helpful. I did something similar recently welding the muffler on a ATV. Had to cut, grind, patch and tap. Learned some tricks here, thanks!
Thanks for taking the time to share your experience and skills with me. I’ve learned a lot
Excellent detailed process. Very educational.Thank you
One of the best videos ye made every body can weld heavy gauge this takes real skill to do this keep it up 👌👌
Lots of beginners mistakes there. I did those when I started learning bodywork.
First of all, you identify the clean metal all the way. Wire wheel on an angle grinder does the job.
2, you take a sheet metal (proper size or close) and lay it on the piece. You work the piece out until you get the perfect fit (same curvatures as the original metal).
3: you secure the metal to the base piece with 2 small weld points. You make positioning marks with a scraping tool on 3 or all sides of the repair piece
4. You take a 1mm cutting wheel and cut through both of the metals (if you did not make the repair section a perfect fit) or cut along the edge of the repair section, with the repair section in place so that you won't have to fiddle with it after. I recommended letting the long straight edges to be cut at the end; start with the curved edges of the repair panel. This way you will have a nice even gap. The small tack welds you did will be cut at this stage, if this is what you are asking.
5. Start welding in taps just as you showed. That one and the air blowing are perfect technique. Tech tip: If you blow holes at the bottom and you can't set the machine to the perfect setting (yes, for those of you with vintage or cheap machines), you put a thick copper plate underneath the place you weld. Metal doesn't stick to copper. Don't use aluminium, it's shitty. Beware of the burned fingers because of the copper plate!
6. Use a hammer and dolly to beat the welds in order to avoid heat distorsion (weld 2-3 spots, hammer them a little - it also gives time for the metal to cool)
7. Use the same 1mm cutting disc in the cutting position (perpendicular to the sheet metal) to degross the weld where excess has build up. Tech tip: don't try to obtain pretty welds; those don't have enough mechanical strength. Do strong all the way through welds and grind the excess after.
8. Use a flapping disk (160) to surface up the metal if you need to. Beware that the flapping disc makes a lot of heat, you have to move quickly or the metal will wrap. Don't use this disc to degross the welds. You will have wrapping in your sheet metal.
9. Admire your work, because you did a very good job. :)
You should also take some photos before and after the repair, just in case you had some details you missed.
All of these are learned in years of self training. Self experience, thinking and getting tips from other people on TH-cam. Hope you can find use for what i told you.
I saw a technique for cutting the panel like in step four but you cut on a slight angle (angled with top of wheel toward outside edge) . This leaves a gap smaller than the thickness of the cutoff wheel.
@@bretlovitz3068 think i saw the same vid. Gas tank door on a truck bed right?. Let's you get it nice and flush real quick and easy.
My dad made me start on the thin stuff and i havent regreted it helped me learn my welder and the settings and how precise you need to be
Great video! I wish I had someone to share this info with me when I first started doing body repair. Sheet metal eh, its something.. I’ve been doing it for about four years now and while it does generally go a lot quicker now I still have trouble with it. It’s just plain tough to weld sometimes. All I can say is I am very glad I don’t do sheet metal work for a living lol..
Loved your honesty! That's real welding
Great video. Learned a lot. Thanks.
Great video! Same to all Weld.Com team, stay safe.
A lot of helpful tips for the rusted through horse trailer I'm about to get on. Thanks man!
Mancube your doing a great job !!
I’m gonna try this technique on my lawn mower. Thanks.
You're a great teacher, thanks!!
I really enjoy these videos especially when you make a mistake and call yourself "dumb ass" That was good. Keep up the good work on videos and teaching the rest of use.
Love seeing more of the mancub on the channel keep it up buddy
This was exactly the video I need. Ive been doing an old BMW restoration and have been getting comments about my welding technique on sheet metal. Everyone thinks I should be laying dimes and its been frustrating trying to correct them that that isn't how sheetmetal works. Also I'm on .030 at the thinnest so I understand the pain of trying not to blowout the weld but I can't always get a copper block into the areas I'm trying to weld.
Thanks bud, for teaching and for clearly teaching. I'm hoping my son as he finishes high school will take welding on as his skill and trade. All the best!!
Good tutorial. I don't have a lot of experience welding thinner gauge so this will help me as I practice.
Great job.I like how you show how to fix the little messups👍
Great Job!
Now I know what I've been doing wrong with thin sheet steel!
Thanks Much, Stay Safe, & Have Fun Learning!!!
James thank you. I try my best have fun learning or get mad cause it not perfect yet.. lol. Thanks for watching weld.com. stay healthy
I can weld it up 👌🏻 it’s the last steps ( every thing between letting the weld cool down and spraying it up for final colours and sometimes cutting up the patch panels and or getting the right shape and templates ps. Good to know I’m not the only one who has done your mistakes of not labelling the paper or metal replacement peace and yes l laughed out loud as I thought 💭 was funny 😂 especially when you said way to go dummy or the stubborn corner weld as I’ve been there done that and had the same thoughts aka not laughing at you personally ) that get me every beeping time. I’ve tryed two different times and on different projects ( one of which I warped a USA made in st. Lewis Missouri 1980’s original steel sheet metal pickup fleet side beyond economical if at all repair mostly from grinding/ linening/sanding and adding insult to injury as it was my first time trying to fix gas filter/rust repair/dent repair and yes I added more distortion from me as of right now I’ve got a better handle on that and no longer have warping or blowing weld through problems on the regular and I found that I like tack mig ing ( because it’s quicker and easier not playing 4 arms/can hold up my work better ) before final tig welding at least for me that’s how I get the last amount of distortion and weld porosity and unwarranted harding ect. and the least amount of grinding out the bad sections and having to rework the panel ) and right now I’ve pretty much surrendered to 💰 paying someone off to do it right ( or waiting or someone to teach me in person/going to school for it or I weld it back up you clean up my mess / do everything thing else needed to weld it up and pay someone money 💵 or trade time / skills ) or sell off what ever has a rust hole ( I did that once to a really nice 1968 c10 that I couldn’t bring myself to Butcher or bugger it up as it wasn’t a cheep I don’t care demo Derby, mud bogger,crawler or race car 🏎/truck and had potential for winning a car show. all I hope it the next guy had better luck at fixing the cab corners and flooring than me as I kinda regret selling it as it was so good to me ) ( especially if I care about it having a chance of it being restored to showroom condition ) that or I don’t care attitude and bog weld fresh new panels ( fix it but skip any body work aka it ant rusty but it’s ugly and dented from me or it’s life before me aka drift misslle or cheap race car ) it without any rust
There’s a cool 😎 method of using a torch to move the metal around and I wish I had a better understanding and handle on shrinking and stenching with it to remove dents or things like that one last corner weld in the video to flatten it out.
AlwayS a great video 58 yrs old a mechanic for most of my years NOT A WELDER but I follow your instructions found in your videos and I purchased a flux core welder and I am really coming along it’s been a year and for my own work it is very “not bad” lol thank you guys BK in CT
Thanks for the support
I wish I could use a 4.5" cutoff wheel with that precision, especially around a tight radius. Nice work
it's all about practicing
Use a hole saw in your corners less clean up no oops moments with a death wheel
Great video mate, I have been doing some small patch repairs on an old vehicle and was "bridging' but wasn't sure if it was a done thing. You have now re assured me that's it's all good!
Great video awesome content! 👌👍🤙
U are great sir
This video is best video
Learning is key,that is the nature of the work ,keep pressing forward and u may be very happy with end results.Good work
Great job! If you want to see a different take on butt welds check out Fitzee’s Fabrications.
Fitzee-z-da-man.....
Excellent details. Outstanding video!
Excellent demos of how to weld real world crusty rusty repairs. Same with the last one (the motor part). Wish I could weld on shiny new plate all the time (Haha, without actually having to get a job doing just that ;) ), but a lot of times I'm just cobbling something together out of whatever I have on hand, or fixing something to get some more miles out of it, or building something up out of pieces to machine (because I can't afford to just get a huge chunk of steel and make chips out of most of it). Thanks! Keep it up.
awesome video! it's great to see mancub getting more comfortable with the camera! you've got a lot of skill and i cant wait for you to put it all on display!
Thanks buddy.There slowly letting me out. I have alot to share and I have alot to learn. Stay healthy. I appreciate watching weld.com
Awesome Vid brother!! I learned that I’m gonna need more patience! 😂 That seemed tedious and methodical! I hope I have the opportunity to at least try this one day! 👍
Shaun thank you buddy. Stay healthy. Thank you for watching weld.com
Nice work, thanks for posting.
Like your corner idea - nice work
Fantastic! It is awesome to see you guys using something I am welding also!!
Welding rusty sheet metal is an art form
Love these kinds of videos. Would like to see more of them.
Great video. liked all the details he talked about
Thank you, now I can fix my mower deck.
lesson No 1, clean off the paint and metal to find your thin spots etc before cutting, that way you wont have to cut out a bigger area when you find you haven't taken enough.
Man cub actually surprised me abit on this one but as a metal shaper and coach builder who does this everyday heres a few small tips for you guys never use a pointy hammer like that. get some dollys and with each tack grind it almost flush and hammer and dolly the tack this will stretch the shrunk weld and stop the gap closing up once you see the gap open up move to the next tack and repeat the process then do the same thing but with bursts like mancub did then once again grind almost flush planish the welds and move on to the next one this will eliminate distortion. once finished that process blend in and planish for a seamless weld
I've been looking for a video like this for a long time. Thanks ManCub Welder!! Kieren Meier if you could contribute your own video demonstrating your technique that would be extra great. I was studying TIG welding (until the plague hit, cancelling class), hoping to develop the chops to attempt something like this. Every bit I learn puts me one step closer to actually getting it done. I'm going to be watching this video again and again and again. Anyway, great video!!
@@normanklein3155 if you look up wray schellin he does a very similar technique also Peter tomasini does a demonstration with gas welding panels in the same way it's more of a panel beating technique rather then regular welding knowledge. most people in my trade are usually pretty average welders because we do alot of tack welding and weld little sections at a time to keep the heat down so in reality you don't need as much welding skills as you think your settings will be abit more important though so make sure you take the time to dial it in on some practice pieces first.
Thank you!
great video, thanks for presenting.
Excellent content bro.
Mountain Eagle thank you. Thanks for watching. Stay healthy
Pretty helpful. I am restoring a 59 Chevy Apache
Very informative. I wanted to know where to start on patch panels.
I weld thin metal in this same fashion except i use fluxcore. Works for me👍. Great video, thanks for sharing.
In welding school we used 3/8 plates. On my first weld job I had to tack thin steel curtain plates . 🙄Thanks for the video.
Super interesting, thanks man. Have a great day.
That's a legit vid right there. Thanks 👍 Gonna help me big time with my floor pans.
Trunk panels ( one of the common rust spots ) in a 60’s Charger?? I know that I’m not looking for mine to be replaced ( most likely going to have to pay 💰 someone else to fix it right or at least get help or bring myself to I don’t care and bugger patch it ok welds just the rest sucks # race car 🏎 more than likely I don’t think 💭 🤔 that I can bring my self down that low ) o well mini tub 🛀 time ( from auto metal Direct / year one or classic industries ) that and the transmission tunnel has to be widen / taller out / changed to fix my new T56/TR6060/TR6070 manual Transmission case which if it’s not a numbers car I highly recommend that you change it at the same time as the rust repair/replacement because most transmission designs / made after 1980’s ish don’t fit including the automatics ie. like the 6l80e from Gm
I’ve got some other body work on that Charger and my 86 K1500 that I’m not looking forward to besides that trunk floor replacement as mine it pure minty fresh Swiss cheese 🧀 because of a bad trunk gasket and the prior owner doing bleach burn outs and the cardboard and tar gas tank liner that they used from the factory in 1965-76 for NVH and rubbing a hole through the gas tank or body
Who is this guy? Haven't seen him on the channel! I like him. Hes not the perfect welder that does it all right, all the time like 99% of us. Granted I have learned A LOT from this channel. Started mig welding at my most recent job and I have only "welded" about 20 minutes prior to spending days welding on rusty, dented, messed up roll off dumpsters. Im actually running good structural beads now, at least I think so. For having brake rotors dumped on them from 20 feet high lol. Thank you for your video my man. New thing to try out when I get time
i love your guys videos....but i do alot of sheetmetal welding/patching. ALWAYS bend your panel to fit before you tack in a patch. because it wasn't fitted well (bent first) there was a big crown in the middle which pulled up the bottom edge and corners. no sense making a template to fit the hole if you dont fit the panel into the hole. oh, and use a piece of tig rod to help fill those large gaps while you're tacking a poorly fitted panel. (like 'texas tig') good stuff tho!
I agree with everything you said, and will go a little farther. I'm an airline mechanic that does a lot of this type work with aluminum. We don't weld. We rivet. I bend, and fit my material first. I then use the filler as the template to cut out the hole. That gives me the perfect gap all the way around.
Done both ways before. I just decided to do it this way.
Thanks for the tig filler rod idea. That's a good idea. Still get the same result. Done both ways before. You can dolly your crown down if you want. Metal will move. You just have to understand it. Both ways work same result. Appreciate watching weld.com. stay healthy
The top is crown naturally. It had a crowm all the way down the hood.
@@mancubwelder1312 wasn't talking sh*t, i appreciate you're videos. and as a guy that does videos, i know how much work goes into what you do, and you do it better than me. at 13:02 you can see the crown in the middle of that bottom seam that i was referring to. if that's how it is (and it doesn't show in video), then that's how it is.
I like your channel, videos, techniques. I think this is educational for my learning.
Cheers..
Real practical, on the job.. thz showing extra dramas that arise along with prep procedures . good info.. thz big boy.b good.. jas
very nice job , well done !
Good video.... pro tip never weld patches with glove on if the panel is to hot for your hand your warping it. 1 to 2 second tacks every 6 inches staggering start points. When form a radius on the fly IE not pre forming your patch start on the sort side of your radius working to the long side. when ever possible not using a hammer. Clean the entire area before laying out a patch. Good video tho. P.s use a flat rasp to knock down high weld points those produce no heat alot of guys do a great job welding the patch but take it to warp town while grinding....... I do this for a living keep the videos coming
Good video--I learned a lot!
Great job on the video!
Awesome learn something every time!
Love it! Great vid 👍🏻
Good work mancub!
Great video man! Good stuff.
Thanks a lot.
Great video today
Good job!
Great video!