Welding Patches

[RustBuket]

Well I did some welding on my tailgate today to get rid of some of the rust but I was having a hard time doing it. How do you make the patch exactly the same size as the hole or what is the trick? I seem to not be able to make a peice of steel the same size as the hole and then I end up with gaps which are hard to fill. Any suggestions or other methods? /forums/images/graemlins/1zhelp.gif

 

[85mudblazin]

just use the piece that you cut out as a template or if there was just a rusty hole then try cutting out a perfect square in the tailgate and then make another perfect square for the patch.

 

[RustBuket]

The thing is, my tool of choice is an angle grinder... its very difficult to cut a perfect square. And also the peice I cut out is smaller than the hole because of the width of the wheel. I don't have the $ for a plasma cutter thats for sure. What other tools work well?

 

[k20]

well, if you are using a 3/16" wide wheel (just a #) just make your measured square 3/16" (or would it be half that....) bigger?

 

[85mudblazin]

are u working with just the shell or is the tailgate on the truck and loaded with all the window stuff?

 

[84gmcjimmy]

I use a ultra thin cutting wheel on my 5" angle grinder, and if I concentrate, I can make a good straight cut.

 

[jrsheets]

Take a piece of paper and some masking tape. Cover the hole with the piece of paper and tape it down. Feel your way around the cut out area with a sharpy marker and you can get a pretty accurate outline of the hole. I've found this is the easiest way to make a good template to cut from. This should work pretty well for you even if your working on a curved surface. I've done a few spots around the skirts of my truck, all came out pretty good with a little layer of filler. Nothing tremendous. Im actually attempting the entire rear wheel well arc panel right now. Its going to be a challenge to smooth out.

 

[RustBuket]

I'm working with a loaded tailgate that is on the truck. It would be easier if it were just the shell cause then I could just weld from the back and have less smoothing to do but I'll keep my eye out for an ultra thin cutting disk and I'll try the paper template trick.

 

[darkshadow]

cut a piece of patch that is bigger than the area you need to fix, cut it grind it relatively strate then use a scribe to mark it on the panle you are working on, a good sharp mark, or use a brand new marker, then cut on the inside of the line.
make it smaller if anything then you can go back and grind it bigger if you need to. /forums/images/graemlins/waytogo.gif

 

[RustBuket]

I think I may try cutting the patch first next time I do then run a felt marker around and then cut the hole.

 

[darkshadow]

sounds perfect /forums/images/graemlins/waytogo.gif
so hows things up there my canadian brother?

how do you have rust out there? they dont use salt!! /forums/images/graemlins/dunno.gif

 

[Fry]

I bought a few good thin cutting discs at acklands, they have a good brand there. Charger or something like that.

 

[RustBuket]

Thanks Fry, I'll try Acklands out. Well you see, in Saskatchewan there is snow for most of the year. And there in the summer, it rains and then dries and rains and dries....etc. You get the idea. There are trucks from like 98 that are starting to rust.... not cool.