RWD - sheet metal welding
                    

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sheet metal welding 200

You've probably practiced some already, and a MIG welder is the right machine for what you describe. Use shielding gas and solid wire rather than the flux core wire for thin sheet metal. 18-20 gauge sounds about right. I use scrap body steel from junk cars for free if it's around. Mild steel is what we're talking about.

For most of my repairs I cut out the bad metal and cut the patch bigger than the whole and do a lap joint. Bend and hammer the patch pieces to get them to fit flush against the edges of the whole you've made. I put the patch on from the back and tack it every inch or so. The tacks are easy to grind flush, and then I use bondo on the recessed patch. You can do butt seams if you want, and you can fill the whole edge of the patch with either technique, but go gradually to minimize warpage from heat build-up.

I'm self taught mostly, and I recommend having a look at some body work manuals for other approaches. There is no way around practicing to get good at this, but read up some, and get on the right track. It's very rewarding to have this skill under your belt.

Good Luck,
Steve




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New sheet metal welding [200]
posted by  Michel  on Fri Jul 3 10:52 CST 2009 >


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