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

Looks better than I could do...(especially since all I have is an ARC welder (220V) and a flux core p-o-s Harbor Freight 110V "welder--more like" hole blaster" if you attempt welding thin body metal )...

One trick I've used a few times on thin stuff or wide gaps,is to take a hunk of copper tubing and smash it flat with a hammer,and put it behind the gap if possible...the copper will not weld,and it will help allow you to build up a puddle big enough to fill the gap without blowing through..but its tricky,welding one handed while trying to hold the copper in place,plus the copper gets REAL hot quick..
 
bp71k5 said:
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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Well thanks guys, I really felt I might have jacked it all up.

@bp71k5 I noticed the body line issue prior to welding, it's almost like that post had a very slight twist in it. I tried to "undo" it in a vise but I was afraid to clamp it too hard (to hold it while I pulled) or pull too much and end up going too far. The truck is just a wheeler so I think it'll bondo out. :thumb:
 
Yeah, I was expecting yours to look like mine did when I first experimented with sheet metal welding. I don't think you will have a problem, big thing you appear to have avoided was any severe warping :waytogo: I could not say the same thing with my sheet metal welds...
 
Thanks again. I still think it's awful though. You know how it is, you (I) sit behind a desk all day looking at other people work on the net and that junk is beautiful. I've read a ton, watch YouTube and looks at countless builds, I thought for sure my first welds would look like a stack of dimes. :rotfl:

As for warpage, I think it's just luck since the pillars don't really have any long flat runs, plus some areas are thicker. The real test will be the 6"x6" B pillar cap patches.
 
Sheet metal stuff never looks like a stack of dimes. A little less aggression would mean slightly less grinding, but really it's fine. Penetration is never the issue with thin sheet, so get it burned in a neatly as you can and spend the time with the grinder, die grinder, and whatever other grinding shaping tools you have. You want to be careful though and not try to grind too much. It's possible to thin the whole area if you get too carried away trying to grind to perfection...

Take the top of the weld down gently until you're just a hair above the sheet metal. Then switch to a flap disc and give it a buff and not much more.
 
I just burned a rocker panel to a car last weekend, which must be 12' of tack welds. You just have to keep hitting it in short bursts, grind it out and re-weld anything with holes. When you're done, the welded area has more strength than the base sheet metal anyway. For something as small as an A-pillar, you won't even need Bondo to get it clean. There are no "beads" with sheet metal.

A grinding wheel is only good to save money on flap discs. For getting metal smooth, the flap disc rules. It's also way faster than a grinding wheel. For the larger bumps, you can cut them off with a cut-off wheel, which is also faster than the grinding wheel, before using the flap disc.
 
Right on! Now that you've started it will only get easier.

I have done bad welds and good welds...patients is the key for sheet metal. I actually really enjoy it if I got lots of time.
 
EVERYone was a newb to welding when they first pulled the trigger. Even those considered the best. Dont sweat bugger welds. You will get good feedback here to help you. This Isn't Pirate. :D
 
I'm also using .025 right now. I typically keep .035 in it for the rare occasion I practice on thicker stuff.
 
rdn2blazer said:
EVERYone was a newb to welding when they first pulled the trigger. Even those considered the best. Dont sweat bugger welds. You will get good feedback here to help you. This Isn't Pirate. :D
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Good point rob. Never once have I seen someone get flamed here for bad Welding. Especially the guys that are up front about there skills and are looking for help.
 
beags86 said:
Good point rob. Never once have I seen someone get flamed here for bad Welding. Especially the guys that are up front about there skills and are looking for help.
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Ha, I was a college kid who knew nothing about these trucks when I first joined here.... with the guidance I've gotten I have gotten some really tricky (to me) stuff done.
 
beags86 said:
Good point rob. Never once have I seen someone get flamed here for bad Welding. Especially the guys that are up front about there skills and are looking for help.
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I got myself banned for a month sticking up for a member on Pirate who posted in the "pretty weld thread." His wasn't so bad it warranted that bs. So I took it upon myself to Bite back lol. Of course those clowns love the mob mentality over there vs reason and common sence. So I had several of the trolls making comments just to stir the pot.

But no way in hell was I backing down lol. Not with Right on my side. Several got banned me included. I bitched at the mod for banning me. Told him he was dead wrong. I'd do it again in a heart beat. Like I need that site for a damn thing I can't get here. Joined here and have never left. In fact I never go there anymore. f'um. :D
 
It rained some today so I couldn’t pull the Blazer out to grind on the windshield frame soooo... I decided to start on capping the B pillar holes. I’m feeling pretty good!

With all you guys help I think I’m getting the hang of it! Check out these pics, I feel like my welds might still be “tall” - what say you??

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64F0A30A-AB4D-45EB-BFD4-A229F4BE3ED8.jpeg

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Looks pretty decent to me. Like I have said in my other posts, I am not an experienced welder. But, what helped flatten out my welds was slowing down my travel speed.
 
That looks just fine John, it's all about getting it welded without burn through, then dressing it down later. Sheet metal is just tedious and difficult...

If you want a confidence boost weld some 1/8" steel together now. You'll find it dead easy, and it'll look really good too. Welding sheet metal is like trying to light a cigarette with a flame thrower.
 
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