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  #31 (permalink)  
Old 04-29-2016, 11:18 AM
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Small issue.

Out with the old and in with the new!

Got the patch panel cut at 3/4" below the bend. Found out that the 3/4" wide blue painters tape makes a good way to mark the line to cut. It's starting to look good. I have not flanged the panel yet. One side is a little short, about 1/4" maybe 3/16th." I'm sure the whole thing is junk now! (just kidding, at least it better not be junk) I'm thinking I can just weld on a little piece right there from the not using part of the patch panel. I think I do some of my best thinking right after I post. I think if I center the patch panel and split that gap between the two sides that it might not be too bad.
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  #32 (permalink)  
Old 04-29-2016, 12:00 PM
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Quote:
Originally Posted by Chucky5150 View Post
Out with the old and in with the new!

Got the patch panel cut at 3/4" below the bend. Found out that the 3/4" wide blue painters tape makes a good way to mark the line to cut. It's starting to look good. I have not flanged the panel yet. One side is a little short, about 1/4" maybe 3/16th." I'm sure the whole thing is junk now! (just kidding, at least it better not be junk) I'm thinking I can just weld on a little piece right there from the not using part of the patch panel. I think I do some of my best thinking right after I post. I think if I center the patch panel and split that gap between the two sides that it might not be too bad.
Total gap is closer to 5/16"
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  #33 (permalink)  
Old 04-29-2016, 12:35 PM
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Is that patch galvanized metal?
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  #34 (permalink)  
Old 04-29-2016, 12:48 PM
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Originally Posted by cozwurth View Post
Is that patch galvanized metal?
Looks kind of like it is. It must be light coat or something. I don't see any big chunks of zinc on it.
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  #35 (permalink)  
Old 04-29-2016, 03:04 PM
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That old patch panel might have been galvanized, or maybe just dirty with weld smoke.

Your call Chucky, on whether to center the panel or extend one end of it. Maybe do some welds on scraps to see how that goes and help decide. I like to use 2K seam sealer on a spot with a little too much gap, especially around a window area. It stays better.

Another option might be to make little L's that you could plug weld under the ends of the patch (just the part that faces up) then plug weld the other end to the side panel once the patch is in. That would fill the gaps there and probably hide under the molding. Are you picturing it?
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  #36 (permalink)  
Old 04-29-2016, 06:10 PM
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Isn't it bad juju to weld galvanized metal? Maybe I'm remembering something wrong that I thought I heard?
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  #37 (permalink)  
Old 04-29-2016, 06:15 PM
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Quote:
Originally Posted by cozwurth View Post
Isn't it bad juju to weld galvanized metal? Maybe I'm remembering something wrong that I thought I heard?
It isn't good to breath in the fumes from welding galvanized metal. The right way would be to grind it off where it will be welded. The wrong way is to just say you will have a glass of milk after welding. As far as I know it doesn't do anything to the weld.
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  #38 (permalink)  
Old 04-29-2016, 08:46 PM
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Basically, when welding galvanized metal you are breathing Zinc, you are taking zinc into your lungs, NOT GOOD.

Wear a respirator and have good air movement.

Listen, that one little project isn't likely to be a big deal. I have guys welding the stuff all day long without protection.

But I also know of a guy welding a Honda radiator support (all late model cars are galvanized) in a corner of the shop and ended up in the ICU that night with his lungs pretty screwed up! They will be screwed up for life! I mean REALLY bad with a shunt in his chest that he shoots steroids into his body with.


Brian
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  #39 (permalink)  
Old 04-29-2016, 08:51 PM
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After doing some test fitting. Ok, I just slapped it in place and clamped it down right now. It did take some work to get it in place. I'm thinking not to flange it. I was the tool and the way the bends are it'll only flange up the lower 3/8ish of the patch panel. I would have to cut more on the body to make that line up.

To my rookie eye it looks like a few plug welds and a weld across the seam / corner and I'll be in business. I even checked under the patch area, it seems to line up good. Is there something I'm missing or looking over?
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  #40 (permalink)  
Old 04-29-2016, 11:14 PM
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I have to tell you, there is no way in hell I would weld it there! I hope you don't plan on welding it there, you are going to trim the old down some aren't you?

That corner is very critical for the moulding fit. Unless you want to make that whole area out of bondo which will be very vulnerable I would re-think that weld if that is where you are planning on welding it.

Brian
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  #41 (permalink)  
Old 04-30-2016, 09:44 AM
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What are you going to do with the big gap on the right side?
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  #42 (permalink)  
Old 04-30-2016, 03:18 PM
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Making progress

Quote:
Originally Posted by MARTINSR View Post
I have to tell you, there is no way in hell I would weld it there! I hope you don't plan on welding it there, you are going to trim the old down some aren't you?

That corner is very critical for the moulding fit. Unless you want to make that whole area out of bondo which will be very vulnerable I would re-think that weld if that is where you are planning on welding it.

Brian
I moved it down 1/2." That seemed to work out well I think. I can also take a little more off if need be. The weld seam looks like it would land right on that flange lip. I still got a few high spots to work on, but I think it's coming out good.

Quote:
Originally Posted by idrivejunk View Post
What are you going to do with the big gap on the right side?
I was thinking about making a little piece of metal kind of like this (should be the first picture). Plug welded to the body and that would help fill in the gap. What I have now is real thin, maybe 22 gauge. I can pick up something thinker from the hardware store or even use up some of the patch panel I cut off.


How much, if any, of a gap should there be on the left side right now? There is a little space there as it sits. It will be easy enough to close up that gap if need be. I just didn't want to cut anymore off the patch panel right now.
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  #43 (permalink)  
Old 04-30-2016, 04:36 PM
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Yeah, now you're talking. With the piece you made for the right side. That doesn't look like it will interfere with the molding too bad since the side panel is half rotted away there.

I think on that left side I'd continue trimming the top corner as needed so that it will jam up against the side panel for a weld there where the factory brazed it. No gap, or a very small one. Kinda your call, you are the one who has to weld it up somewhat then grind it nice.

The new edge trim job leaves a little much gap there on your right end and doesn't fit very flush to the old panel's face. Curious to see how that looks screwed tight. If that difference only exists on the right end, flattening the new panel just a little with a shoe sole on the floor might help it.

You're on the right track, and this is probably less tricky that what I suggested as far as appearance and fit, but its more work and probably a safer bet. Looks like your new flanger works real nice!

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  #44 (permalink)  
Old 04-30-2016, 05:29 PM
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That fold where the window moulding goes at the edge looks in too much (the blue line.) Like the patch panel wasn't long enough there from the bottom of the pinch weld (the red line) to the top of that fold (the blue line). If that's the case you want to raise it a little (the green arrow) raising the yellow + a little is not a big deal. If that has to be done understand, you could do this being the location of the yellow + isn't critical at all, where as the blue line fold is SERIOUSLY critical.




Does that fold on the blue line fall in the exact spot as the old one?

Brian
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  #45 (permalink)  
Old 04-30-2016, 06:21 PM
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I know there was more brazing that I had to remove on that side. The blue line matches up to the same place on the b pillar for the left and right sides.

It is hard to tell just how far off the patch is as there is a gap between the flange and the body in that area. Would it hurt anything if I popped a few self tapping screw in and pulled that gap closed?

Ok, went back. Did more checking it out. Took even more pictures because everyone likes pictures. I think that when the gap gets closed up that it will be close to where it needs to be.


Regarding plug welding, how far apart should they be? My hole punch is 5mm (aka 3/16ish"). Also how far from the ends (left & right) should the first hole be?

p.s: as it is now 7:30ish I think I shall be done for the night.
p.p.s: Thank you guy so much for taking the time to share your knowledge with me. Wouldn't have been this far along without the help I got here.
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