mig welding CIP1 body panels to vanagon.

[westina]

Hi folks.Just placed an order for 2 rear lover corners, 2 front door step panels and left side rocker panel from CIP1. Anyone welded them before to their vehicles? I have limited experience with flux core wire and this new unit can use gas, it has a regulator and gauge, i need to figure out how to set it up and where to get gas.
My understanding with this panels are, we need to tack weld paying attention not to warp, taking your time and fill a bit more between the previous tacks.
Is it possible to achieve end result that doesn't require body fillers etc or it is normal precedure to use bondo or similar stuff. Thanks

[orwell84]

You will do way better with gas. You can get it at any welding supply outlet. You will have to rent or buy a tank outright, but it is well worth the expense. When it's empty, they give you a full tank. It doesn't cost that much for a refill.

Repairing body panels without using filler requires a high level of skill beyond just doing good welds and is an unrealistic expectation for a beginner. There is nothing at all wrong with filler when it is used correctly and is not too thick. 1/16 inch of filler is considered decent work, 1/8th is considered ok. Body filler's bad reputation comes from people who use it improperly.

[theKbStockpiler]

Filling the gap method is better than a flanged overlap joint.
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[westina]

Thanks. My panels should arrive in a week or so. I see no problem doing welding in cold weather right? I may have to wait on other works such as bondo, fiberglass resin, paint till outside temps goes up again in spring.

[57BLITZ]

[westina]

[57BLITZ]

[theKbStockpiler]

You can adjust the heat by how much you overlap the last tack weld. The denser the base of the material is ,the more heat it can absorb with out raising the temperature. Usually the issue with not overlapping is that the fit up has to be perfect which is next to impossible with hand tools. So the gap takes care of that. If it shrinks too much you can "hammer weld it" which is just hammering/dollying the seam when it is hot. You can also do it while it is cool. I have never had a big issue with shrinkage when using the gap method so I think it is over emphasized.

As far as ambient temp goes, it's really only an issue if the metal is under 25 degrees fahrenheit. Then you really have to pre-heat it.
_________________
My beetle is not competing with your beetle. I have the yellow beetle in my town. There is a red one, a green one ......
Use all safety devices including a mask.

[CiderGuy]

[westina]

Hi. I ll check my wire size, i am not sure what size it is. Panels arrived from CIP, i liked them. fits nice etc. but lower corner piece arrived damaged. Also there is a ridge in the middle of the rocker panel. Its not too bad i am not sure if it would show after getting it installed.
Anyway i have started the body repair part of the project. Still couldn't find the sweet spot with the mig. Also the only gauge i was able to find local was 22.
At my skill level, i probably will apply a layer of shortstrand fiberglass bondo or some other variety and smooth it out and paint.
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Fell free to make suggestion. I ll update as i progress. [/img]

[CiderGuy]

You might want to look into .023 Easy Grind wire. Plenty on the web about it, good stuff. Measure 3 times cut once.
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Cars Currently Owned:

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Timing is everything

[theKbStockpiler]

I appreciate how you are cutting pieces out instead of using filler.

Part of the issue with fit up is if you have a patch piece that is a little off ,how much better is it going to be (or worse) the next try. You really should not settle for anything thinner than 20 gauge.

As far as the works goes it looks like you have the idea down but you have to have more experience to fine tune it. At your experience level I would limit the built up bead by not arcing as long. Once the pool stops spreading out ,it builds up. It's easier to start your next weld pool off your last.Overlap the last spot weld by about 1/3 and the capillary action will do the rest. You just have to have more then one series of tack welds going so the heat does not build up as much in one place. I do three weld pools in row arced off each other and then move to a different spot or let it cool down. I let it cool down from being red and than arc a again but not more then three in a row of the same stitch weld. A bunch of spot welds in a row add up to a stitch weld.
_________________
My beetle is not competing with your beetle. I have the yellow beetle in my town. There is a red one, a green one ......
Use all safety devices including a mask.

[57BLITZ]

[beetlenut]

[westina]

Hi, thanks. Checked my wire its 0.23. I cant pick a hotter seting cause its burning holes. I was able to find 22 gauge, which might be too thin. The other available gauge around is 18, which i have a feeling that it would be hard to cut and shape with limited tools.
Its a lot of work, especially trying to achieve stitches without pinholes.

[beetlenut]

[57BLITZ]

[westina]

[westina]

Another lesson learned. I should have cut out the rocker panel first and use the good metal off of it for the repair areas. Upper part was really nice and solid steel.
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I have a question.. Is welding from outside always the proper technique? I just played with the idea that i can weld it from inside the van and maybe overall appearance would be more neat? [/img]

[beetlenut]