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Old 05-08-2012, 03:45 AM
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Patch panel gone bad!

I've been cutting out rust on my 56 belair and replacing with new patch panels. I did a lower door skin, a rusted out lower door hinge mount and cowl area and a few other areas as well. They all came out pretty good, BUT, now i'm in the rear quarter panel right behind the door. I welded the panel one spot weld at a time making sure that I didn't overheat it and was careful when grinding as well. The area above and below the patch sunk in about a quarter of an inch! I didn't realize it until I was done and put a straight edge on it. Do I have to start over or is there a way to stretch the metal back out?

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Old 05-08-2012, 05:07 AM
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Hammer & dolly it back out the best you can and fill it ..You cant expect perfection right from the start and that dosent sound so bad..
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Old 05-08-2012, 03:18 PM
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He means hammer on the dolly to stretch it out, but only on the weld itself.
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Old 05-08-2012, 03:32 PM
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The shrinkage that has occurred is going to be along the weld and discolored heat affected area. If you can stretch that area out the panel will come out. Assuming you welded it with a MIG it will take a good bit to stretch it back out but as Deadbodyman said 1/4 inch is not a whole lot. You should be able to get a lot of it out. Keep your hammer on dolly and only work the weld area.

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Old 05-08-2012, 04:00 PM
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Be sure to grind the Welds (only!) to about .040 above the Metal (both sides) so that you have something to work with-
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Old 05-08-2012, 04:05 PM
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Excellent point. You can't work them if they are not smooth......
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Old 05-09-2012, 12:32 AM
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There's more to metal working than I ever imagined!

Thanks for the advise! I've been reading up as well on the heat affected zone (haz) and it makes a little more sense now. I didn't have much time today to work on it but the time that I did spend helped a little. The car is gutted so I can go through the access in the door panel to hold the dolly. You almost have to have 2 elbows to get in a position to hold the dolly and hammer! I welded a 1/2" black pipe to an old dolly with a bolt holding them together (so it can swivel) so I can hold the dolly in the right place and get some pressure against it. It seems to help me because I'm right handed and I can't hammer with my left hand very well. I was worried that I ground too much of the weld off already but .040 isn't much. It just seems like you have to have more weld so you can "squish" it down and stretch the metal out. Without the the help of everyone here, I really could have messed it up! Not that I'm out of the woods yet by no means! This patch started out as only a few pin holes and it keeps growing. I saw a couple more pin holes in the very top of the quarter panel in front of the tail light. Do I have to cut them out and replace them as well? They're a foot apart and right on the top. What would cause that?
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Old 05-09-2012, 06:51 AM
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Some pictures would be helpful. If the pits are from rust on the outside then its easy to tell how much rust is there. If the pits have paint around them then they are rusting from the inside and could be only the tip of the iceberg. You should be able to see that area, either through the taillight opening or from the bottom.

When stretching the weld be sure to put lots of pressure on the dolly and make every blow on the dolly. The reason for leaving some of the weld on is to be sure you don't undercut. If you planish without grinding the weld down then you are just flattening the weld bead and not stretching the metal.

When oxy acc torch welding the bead is planished while red hot to blend into the metal, and has to be done repeatedly while welding to keep the shrinkage under control, due to the masive heat affected zone.
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Old 05-09-2012, 10:51 AM
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I'm trying to upload pics but my computer teacher (me) forgot to show me how. It says that my attachment is too big for one pic.
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Old 05-09-2012, 11:26 AM
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Quote:
Originally Posted by hinges56
I'm trying to upload pics but my computer teacher (me) forgot to show me how. It says that my attachment is too big for one pic.
It is kinda picky, make it smaller or upload it to Photobucket.com and then post that link here.

Brian
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Old 05-13-2012, 02:17 PM
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[IMG][/IMG] Well, I'm trying to get some pics of my problems. The first is the rust holes in the top of the quarter panel opened up with an ice pick, #2 is the patch panel distorted metal, #3 my next problem, rust in the hood! crap! Before I get carried away explaining them, I'll see if the pics worked.
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