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Old 10-04-2006, 09:29 PM
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Quarter Panel Patch Welding

I put a lower quarter panel patch on my Mustang today. It was made by American Designers. I butted the seams together and they fit very close and tight. I then tacked everything about an inch apart all the way across. I had my wife to hold some copper behind the panel for a heat sink while I welded the 1 inch intervals and not welding any spots beside each other in a row. After each spot that I welded I cooled the spot down with air. Everything looked good until I ground the bead off and the seam area was pooched out too much. Would it be better to take a cutting disc and cut the seam back open, press it back together and weld again or try to work the high spot out? I don't have a shrinking disc but would one work for this problem? I know I could knock it in some and use some filler (I know I'll have to use a little bit anyway) but it would rather have the least amount possible.


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Old 10-05-2006, 07:26 AM
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That pooched out spot is caused from shrinkage along the weldline, do a hammer on dolly along the weld line to stretch that area back out then if there's any stretching this can be shrunk down with a shrinking disc-buy one they work awesome! Also the deformation can be caused from incorrect panel contour-did the panel fit the shape of the quarter well or did you need to use some pressure to get it into alignment, the panel should be installed in a relaxed state or there will be more pulling and distoration as the weld cools. Chances are the shrinkage on both sides of that pooched area is causing the bulge. As a last resort I'd cut it and reweld it like you planned but it really shouldn't be needed if the contour and fit was good on the patch before you started welding.
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Old 10-05-2006, 07:41 AM
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baddbob, it was in a relaxed state when I started tack welding and the fit felt good. As I tack welded across it got tighter but nothing that I couldn't control. Should I have started tacking in the middle and go out? When I was doing the actual welding I started in the middle and welded in different places to keep the heat down. It seemed like it expanded somewhere between welding and grinding. I was even careful to cool it off when grinding. I tried the hammer and dolly but it just seemed to reverse the problem. I'll work on it some more and see what I come up with. Thanks.

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