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Windshield frame, gaps, bubble gum welds - > New General Welding Questions

nvrenuf

nvrenuf

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So I'm back to messing around with getting my windshield frame prepped to weld up (full top conversion). A stock windshield opening is 23.5" from pinch weld to pinch weld. When I set my upper frame in place on the posts (with alignment dowels to hold it) I've got about a 1/8" gap all the way around. As a novice welder I have no idea if this is ok (fillable) or too much. Can this be welded as is? If not, options?

Since there's a rubber gasket around the glass is there enough fudge factor to push the posts flush and weld them (taking the opening from 23.5" to 23.25")? Am I worrying too much about getting the measurement perfect?

IMG_2056.JPG
 
I am a novice welder myself, but having been in the same situation with a welding project I did, I chose to section in a small piece in the gap because my welding abilities where not good enough for a weld fill that big.
 
Thanks guys! The idea of filler material never occurred to me until @83ChevyK5Blazer suggested it. I'm not a fabricator so I have a tendency to only think 2 dimensionally. :doah:
 
You can bridge that, but t'll be tedious. I'd run a series of tacks around the bottom of the joint to help close the gap first. Maybe even two laps, then let it cool. Then the gap should be under 1/16" and manageable with some patience. Even so it'll probably suck in some by the time it's done. You may end up at just under 23.5", but not so much as to cause windshield fitment problems.
 
As you now know it is doable... In the welding class my work made me take we had to fill 1/8 gaps as part of an assignment, so I'm guessing it's not out of the norm.
 
I keep telling myself I want to take a class but there just aren't enough hours in the day.
 
Doing my windshield frame scared the crap out of me, so bad i put it off for 2 years but once I started I was amazed at how well it actually went. I measured for days clamped like hell and it still pulled and had gaps to fill but in the end the windshield went in like butter.

1-31-09 004.jpg
 
nvrenuf said:
No pics of my bubblegum welding will ever be seen! LOL We were at a volleyball tournament this weekend so I didn't get my grinding badge - yet! Next weekend should be clear for sparks. :grind:
Click to expand...
I would seriously post them up. I know it's embarrassing, trust me! I posted my horrible welds up on the miller forum and the welding tips and tricks forum all the time to get some advice from guys. That's what has really helped my welds out. There are some really experienced welders on here (not me) that would give you advice without beating you up.
 
I don't know, I might post them up.

I'm the first to admit I have ZERO welding skill. My biggest issue was being too aggressive with thin metal and "going for it" when I saw a decent tack going down. I was constantly trying to go just a little further and would then end up blowing thru which meant coming back and filling / building making for thick, ugly, globby welds. This was also my first attempt at welding anything vertical which was very awkward (standing in the door opening, etc).
 
Get yourself some course flap discs for grinding welds.
I'll never go back to a grinding wheel ever again.
 
Best advice I ever got from someone on here for sheetmetal is to only tack weld it. Never try to run a bead on it. Once you do it a few times, you realize why (and sounds like you already have) and you'll be tons better the next time.

Assuming it's MIG, just hit the gap with a very hot burst (1/2 second) spot and let it cool for a few seconds, then hit it again a little farther over, then repeat lots of times making sure not to go to fast. I'd never claim to be a good welder, but I've had lots of thin metal practice.
 
Ok here we go, check out my bubble gum.

Welder : 120v Lincoln 135a mig

I feel certain most of my problem is being impatient and trying to weld an inch when it needs to be a spot.

You can see big globs, these are mostly where the metal was blowing thru and I was trying to fill it in and it built up.

Right A pillar

IMG_2089.JPG

IMG_2091.JPG

IMG_2092.JPG

Left A Pillar

IMG_2093.JPG

IMG_2094.JPG
 
Ah, you made it sound way worse than it is. Only potential trouble spot might be in the third picture where it looks like the windshield body line on the top isn't quite perfectly lining up with the line on the bottom. Might be able to blend it out ok though. Otherwise looks like everything should flapdisc down ok. Any holes that might appear after grinding can be zapped shut with a quick weld.
 
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