Welding gurus check in please

[lectric80]

I am getting ready to put a patch panel into the B pillar on Krusty. This panel is to repair the busted out door striker bolt that I did a temp repair on last year. I am planning to cut up an old tailgate access panel that I don't need, and then make a dual layer patch panel to weld into the pillar.

My question is that I had heard at some point that when doing this type of patch panel that the corners should be rounded to help prevent stress cracks. Is this something I need to worry about, or would 90* corners work just as well? This is something that is obviously going to see a lot of force at times, and I want it to last for a good long time.

By no means am I an expert welder, but a good stitch weld in this spot I can accomplish. I am just tired of listening to the door rattle because the original patch was some pretty crappy sheetmetal that isn't holding up well. The dual layer patch should provide some stability for the bolt, but I don't want it to fail again.

So, what say you?

Edit: It should be obvious, but a square edged patch panel would be easier to cut out of the pillar. However, I want this to be as strong as I can possibly make it, so I will do what needs to be done to ensure it is solid.

 

[ryoken]

no guru here, but I've done my share of bodywork...

technically, a radiused corner would be better...

but I did exactly what your talking about on my driverside about 4 yrs ago, squared... and it's held up fine, especially considering I brazed it in with a coat hangar...

 

[lectric80]

That's good to know, thanks Paul. Guess I can get going on this little project after the holiday.

 

[RudyO]

A radius is more desirable from a burn through stand point. 90s tend to blow holes more.

 

[lectric80]

That is something I will take into consideration. It may be more work to radius it, since I can't just use my grinder to cut it out, but I can handle it. Guess I could always drill the corners to get the radius then use the cutoff wheel to get the parellel lines cut out. Thanks for the information everyone, I will post up when I get going on this project.

 

[RudyO]

Even with the 90, just take it slow. A 90 compared to a radius just has more chance to build up heat due to the surfaces and proximity of angles involved. Not a master, but did play with trial and error.

 

[RudyO]

Stress cracks will have to do more with the heat treating of the metal. Older vehicles have more metal and are easier to repair. Newer vehicles have less, but are treated to (supposedly) take more damage. This has more to do with the brittleness than the softness of said metal. Older metal is easier to work back into shape. Not sure when the practice gained favor, but would guess the mid-late 70's. I had a 90 p/u, and if you looked near the strikers there were some pretty good stress cracks happening.

One of the reasons glue has gained favor in body shops. Easier and cheaper to repair with it.

*Extra post was after I looked at the year of your vehicle.

 

[lectric80]

I appreciate all the information, it all comes in handy not just for me but for anyone with similiar questions. Just picked up some seats and I need to get them installed, and that sounds like the right time to hit this one as well. If all goes well this project should be done next weekend.

 

[Fabrimacator21]

Like ryoken said the radiused corners should be stronger.

Drilling will work but a die grinder or dremel with a good bit would be best.