Mustang5l5's Progress Thread - Drivers side frame rail using donor piece

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95BlueStallion

Drop into my dm’s gurrrrrl
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I’ve personally come a long way since I did mine. I tacked mine, moving around and around to avoid warping. It turned out meh, but enough to trust it. Yours looks better. Wish I would have used gas, but glad to see yours coming out nice.
 

Mustang5L5

i'm familiar with penetration
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Wish I would have used gas, but glad to see yours coming out nice.
The gas made a huge difference. Was actually surprised how much so. Flux core seemed “hot” no matter how low I turned the power down. With gas, it seemed to penetrate easier with less burn through. Once I got the power and speed figured it, it was easy. Was worth the bottle purchase for sure.

I made notes on my settings. One setting to weld, and then a slightly weaker setting to fill the couple burned through spots where my panel gap was a little big.

I plan to grind the welds on the side just for appearance, but likely leave them in place underneath. Glad I started on the easy side.

Hate to say it, but it was actually fun. I’m probably going to end up filling holes now and definitely will be welding in my subframes myself.
 

Rdub6

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The gas made a huge difference. Was actually surprised how much so. Flux core seemed “hot” no matter how low I turned the power down. With gas, it seemed to penetrate easier with less burn through. Once I got the power and speed figured it, it was easy. Was worth the bottle purchase for sure.

I made notes on my settings. One setting to weld, and then a slightly weaker setting to fill the couple burned through spots where my panel gap was a little big.

I plan to grind the welds on the side just for appearance, but likely leave them in place underneath. Glad I started on the easy side.

Hate to say it, but it was actually fun. I’m probably going to end up filling holes now and definitely will be welding in my subframes myself.
Looking good. I found it to be somewhat “addicting” myself. Definitely a fun skill to be learning!!
 

bird_dog0347

still married haven't seen testicles in years
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The gas made a huge difference. Was actually surprised how much so. Flux core seemed “hot” no matter how low I turned the power down. With gas, it seemed to penetrate easier with less burn through. Once I got the power and speed figured it, it was easy. Was worth the bottle purchase for sure.

I made notes on my settings. One setting to weld, and then a slightly weaker setting to fill the couple burned through spots where my panel gap was a little big.

I plan to grind the welds on the side just for appearance, but likely leave them in place underneath. Glad I started on the easy side.

Hate to say it, but it was actually fun. I’m probably going to end up filling holes now and definitely will be welding in my subframes myself.
The subframes were the only thing I really hated doing, but mainly just because of the angles and getting the welds right while laying on my back with the car not quite high enough.
 
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Mustang5L5

i'm familiar with penetration
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The subframes were the only thing I really hated doing, but mainly just because of the angles and getting the welds right while laying on my back with the car not quite high enough.
Oh, i'm sure it won't be fun. I dispise anything to do while laying on my back under a car.

Still, I was all set to drop the car off at a local shop to have them done. Now, given my investment in the welder, I should actually use the thing. My confidence is going up the more I use it. I spend my evenings watching YouTube vids on MIG welding sheet metal and various techniques and angles. It's been a good skill to learn.

I would have loved to have kept going and finish the rail, but i need to grind the welds down a bit where the frame rail peices is going to patch into place for clearance. I may even add some small stitch welds to the backside of the tower and start working on filling holes.

I'm not going to fill EVERY hole. I'll just focus ont he ones on the towers where you will see the swiss-cheese look plain as day and some of the holes on the aprons. I plan on running a stock Airbox and battery in stock location otherwise i would have gone with the scott rod aprons. I'm not building a show car, just a clean driver. But...while i'm here
 
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kendawg73

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Also picked up some of this stuff to spray inside when done

862BECD9-4A66-4B6F-8A3C-6473EA987D3B.jpeg
I've used a bunch of can's of that on mine... still have some in the basement, I still need to treat the rocker area's, will do that in a couple weeks, I'm going to spray it into any area I can't get too... I've done several coats on my frame rails already.

I do plan on recoating my frame rails every couple of years just for peace of mind... anything to stop rust....

Make sure you put masking tape over the bottom holes in your frame rail, and on the sides... so it don't spray/drip out...
 
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Rdub6

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Dec 29, 2017
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Oh, i'm sure it won't be fun. I dispise anything to do while laying on my back under a car.

Still, I was all set to drop the car off at a local shop to have them done. Now, given my investment in the welder, I should actually use the thing. My confidence is going up the more I use it. I spend my evenings watching YouTube vids on MIG welding sheet metal and various techniques and angles. It's been a good skill to learn.

I would have loved to have kept going and finish the rail, but i need to grind the welds down a bit where the frame rail peices is going to patch into place for clearance. I may even add some small stitch welds to the backside of the tower and start working on filling holes.

I'm not going to fill EVERY hole. I'll just focus ont he ones on the towers where you will see the swiss-cheese look plain as day and some of the holes on the aprons. I plan on running a stock Airbox and battery in stock location otherwise i would have gone with the scott rod aprons. I'm not building a show car, just a clean driver. But...while i'm here
In hindsight, my inside welds came out better than my outside welds on my subframes. I went in headfirst, on my back, and had a good angle. For the outside ones I stayed completely out from under the car and struggled to get a good angle. If I were to do it again for the outsides, I’d go in feet first under the car, on my back, and have that same angle I had for the inside welds..... if that at all makes sense! Basically working right above your chest with the MIG gun.
 

darkfader

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Awesome developments Mike. I had to go back more than 40 pages to get caught up, and your work looks amazing. When I saw your frame rails, I thought you bought another project fox. As clean as the black LX is, I'd have never guessed. Loving the engine work you did. I'm super motivated now to get mine finished up after seeing yours. Great work so far!
 

Mustang5L5

i'm familiar with penetration
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As clean as the black LX is, I'd have never guessed.
I didn't think it was that bad. The towers were solid and the outside of the rails looked perfect. Other than a small bubble on the pass side, I almost wasn't going to touch it. When I started cutting, it was all rotted out on the inside. Tons of sand in there, so I assume it held moisture.

I probably could have done a smaller patch and called it a day, but i wanted to cut it all out and do it right. Now that i'm nearly done with the pass side and my confidence is up, i have plans to take care of the driver's side in a different method.

Grinder wheels came in, so i need to finish cleaning up the weld and see if i can get it all welded up this weekend.
 
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2Blue2

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Sure like your new welder
Its very nice

The patching is looking great, good clean work
This is such good use of shelter in place time
Right on
 

Noobz347

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Here's a geewiz question:

Where do you all generally buy your sheet metal from? It seems like Home Depot is probably not the way to go if doing these kinds of things regularly.
 

Rdub6

Mustang Master
Dec 29, 2017
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Here's a geewiz question:

Where do you all generally buy your sheet metal from? It seems like Home Depot is probably not the way to go if doing these kinds of things regularly.
A Tractor Supply opened near me recently. They had a pretty good selection of smaller pieces when they opened. Havnt been there in a while though.
 

Mustang5L5

i'm familiar with penetration
Mod Dude
Feb 18, 2001
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Here's a geewiz question:

Where do you all generally buy your sheet metal from? It seems like Home Depot is probably not the way to go if doing these kinds of things regularly.
McMaster-Carr.

Prob a few bucks more but their shipping is lightning fast.
 

Mustang5L5

i'm familiar with penetration
Mod Dude
Feb 18, 2001
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Grinding wheels shows up (from McMaster). So I cleaned up the welds.

I did some small stitch welds on the backside that I didn’t grind. Figure that side can stay ugly. I am gonna fill those holes. I just want to get the rail done first. I’ll use a little filler later to smooth it out

Time to clamp my frame rail piece in place and make sure I like it.

CA2EF4A5-494F-48C8-B40B-8D7D3C9FCC21.jpeg
 

Steel1

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Are you doing your welding with 110 volts ?
If so I would imagine the amp draw has to be in the 15 amp range, any breaker tripping issues or are you on dedicated circuit ?
 

Mustang5L5

i'm familiar with penetration
Mod Dude
Feb 18, 2001
32,867
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Massachusetts
Are you doing your welding with 110 volts ?
If so I would imagine the amp draw has to be in the 15 amp range, any breaker tripping issues or are you on dedicated circuit ?
I’m running it on a 15a circuit. No breaker tripping yet. I do have a 20a circuit I can use if needed a short distance away but hasn’t been necessary yet.

Not using max power. To weld the thickness I am, I’m using the machine at about 50% on the volt dial. The spot welds take a bit note power but no issues. It says max draw is 14.8amps. I’m probably in the 7-9amp range although if I can manage it I’ll try to measure.

I did wire the garage with 20a circuits and 220 power but my feeder run to my subpanel is just a huge PITA that I don’t want to deal with right now.
 

Mustang5L5

i'm familiar with penetration
Mod Dude
Feb 18, 2001
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I did some work in the garage last night til 1AM. It’s rreally the only time I can get in there. Got the frame rail all patched in. I thought I took pics but guess not.

Wasn’t bad to stitch it in. The metal is thicker so I could use more power and not burn through. Initial pass was good, but then I made the rookie mistake of welding on top, so the bead is high. Nothing a grinder won’t fix.

I’m only going to grind the inner side in the engine bay for looks. On the outer rail I did fill some holes. I was tempted to start filling engine bay holes but I want to save my gas for the other side first.

I did spray the Eastwood frame coating. Very interesting, thick, stuff.

Just need to spot weld the top plate in, and fold the little tab back over and stitch weld it to the inner rail.

Almost done with first side.
 
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