The Willomet Charger

[AgDieseler]

Side benefit of the Hobart dropping another potentiometer, lots of time on the TIG machine.


Didn’t quite make my progress goal tonight, but I’m planning on hitting it early tomorrow before work.

David

 

[AgDieseler]

It was a longish weekend (and early Monday) of details. I pulled a half day on Friday, and I still didn’t make my goal of getting the front rails “done.”

I underestimated the time required to juggle some kitchen renovation tasks alongside car fab. Also, the Hobart’s new potentiometer died, and so I ended up TIG’ing a lot more than I planned, and while I like the practice and learned a lot, it’s a substantially slower process.

Outer plate burned in


Inner plate ready to tack


Lots and lots of blending original shapes to match the new overlay plates. The original steel doesn’t weld nearly as nicely as new A500 plate, so I’ve got to be careful with the current input and use a slight weave to maintain a consistent puddle.


This gobbles up the hours, but the result is worthwhile


I had some pretty radical tungsten stick-out to get to those corner welds


More time tonight, and now that the front plate details are complete, I just need to start fitting the top plates and get the rear plates tacked.

Closing in.

David

 

[campfire]

I underestimated the time required to juggle some kitchen renovation tasks alongside car fab.

Hahahaha. I believe the old saying is:

Double that estimate and add two hours. This applies to every repair.

 

[AgDieseler]

One rail, fully welded internally, assembled, and tacked externally.






Still quite a bit of finish welding and blending remains. This sub-project really chews up the hours.

David

 

[Tweekls1]

Awesome work as usual, I envy your fab skills!

 

[AgDieseler]

Awesome work as usual, I envy your fab skills!

Thank you. I appreciate that. Consistent practice, a wide array of mistakes, and experimentation has taught me a lot...the slow way.

David

 

[AgDieseler]

Copy, and paste.

Passenger rail is welded internally and tacked externally. I’m planning to close up those open corner welds tonight and tomorrow. Parts for the MIG should arrive tomorrow, and I prefer to use that machine for plug welds.







I’m not yet a strong out-of-position TIG welder, so I’m leaving the overlay triangle welds until I can get the car on the rotisserie...unless I get brave.

David

 

[ClassicStyle]

You can’t have no in your heart

 

[AgDieseler]

Early morning weld session. Lots more to go.




David

 

[Truckman4life]

 

[AgDieseler]

...(mostly) dry aged 48 years.

David

 

[AgDieseler]

Just a bit more to go.





Working the outside plates tomorrow.

David

 

[blazinzuk]

Just a bit more to go.

View attachment 272928

View attachment 272929

Working the outside plates tomorrow.

David

I assume from your spacing and corners these will all be ground down smooth like?

Looks good man

 

[AgDieseler]

I assume from your spacing and corners these will all be ground down smooth like?

Looks good man

Yeah, I’ll lightly blend these. I’m always concerned about taking away too much filler material. I usually just level each face, and slide the DA over the bead itself.

David

 

[AgDieseler]

You can’t have no in your heart

I though of you when I did this. DC pulse: 95A, 55% time on, 25% amps, 0.2 Hz



Thanks for the kick.

David

 

[ClassicStyle]

Only way to get good at it is to do it.

Temp is a little hot, but not bad at all!

Welding In position is tough, next week we’ll do it with our non-dominant hand.

 

[AgDieseler]

Non-dominant hand welding - got some practice on that, too.

I’m adjusting the settings for today. Looking at slightly hotter, but shorter bursts. Part of the problem on the heat input is dwell time, and I’m experimenting with some scrap first. Starting with 95A, 30% time on, 35% amps, 0.2 Hz.

David

 

[ClassicStyle]

I’ve never pulsed, learned from a old school guy and never had a need to try any other way.

And my 351 sycrowave doesn’t have the option. Haha

If I was welding that with my machine, I’d have a 3/32 tungesten, 90-100 Amps. Expecting to be 40-50% pedal. Acquire my puddle, watch for the bright dot of carbon on the leading edge and run my bead.

Control arms are single pass, no pulse.

Subframe to frame connector brackets have a root pass and a finish pass. Again no pulse, just running a bead





I’ll

 

[AgDieseler]

... I’d have a 3/32 tungesten, 90-100 Amps. Expecting to be 40-50% pedal. Acquire my puddle, watch for the bright dot of carbon on the leading edge and run my bead...

Very good looking work. Notes taken.

David

 

[AgDieseler]

Spent the early morning finishing welding the overlay plate. I still have to do the other side, but that will have to wait for several weeks.



The Charger build is idled while I turn my attention and time to suburban prep in advance of its next adventure.



I know exactly where I have to start - finish weld the other overlay plate and start building the floor support structure. If you look closely, you’ll see that 3x1 steel for the floor stored inside the car.

David