Progress Thread The "grátis" 1966 Coupe - final sheet metal repairs

horse sence

15 Year Member

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Wile Coyote's stunt double

Apr 24, 2019

#241

• Apr 24, 2019

• #241

The hardest part about mig welding is seeing the weld as you make it ,seems like the lense in the helmet is always to dark

 

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02 281 GT

Agreed...My wife has great Boobs

15 Year Member

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Apr 25, 2019

#242

• Apr 25, 2019

• #242

@horse sence @Davedacarpainter What are your thoughts on switching to a .024” wire once I’m done with the thick gauge torque boxes? I’ve had at least one recommendation to use the thinner wire with thin gauge sheet metal.

 

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2Blue2

will be trying this sex one when I can find it

Mod Dude

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Apr 25, 2019

#243

• Apr 25, 2019

• #243

smaller wire = less heat= not as happy trying to burn weld thru primer off.. Used mostly for butt welding thin sheetmetal.
But if your burning thru a lot then ya got to find what works for you, your welder and application.

 

Davedacarpainter

Chicks can make things hard if they’re inspired...

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Discordia

Apr 25, 2019

#244

• Apr 25, 2019

• #244

Whut he said^^^^^^

 

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02 281 GT

Agreed...My wife has great Boobs

15 Year Member

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Apr 25, 2019

#245

• Apr 25, 2019

• #245

I’m pretty much following y’all’s advice on the weld thru primer and just doing bare metal now. Almost done welding in the outer torque box. @horse sence ’s sheet metal screw advice was right on the money. Pictures will follow. Gonna get started on the passenger side and will hopefully get that done today. Then it’s floor pan time.

 

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horse sence

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Apr 25, 2019

#246

• Apr 25, 2019

• #246

I use 030 wire every where ,but i am used to it .
Clean the rockers well where the floor will be welded ,it is galvinized and will not weld easily ,only need to clean where the welds will be . A few screws will hold the floor to the rockers ,toe board and rear floor ,just put them right through your plug weld holes and fill in after the rest is welded

 

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horse sence

15 Year Member

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Apr 25, 2019

#247

• Apr 25, 2019

• #247

Check out page two in this link ,i had to do a floor in my nephews coupe ,it doesnt show it but i did clean the primer away where i had to weld ,the floor tool i made may help you also https://www.stangnet.com/mustang-fo...rprise-my-nephew-64-1-2-mustang-coupe.859528/

 

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02 281 GT

Agreed...My wife has great Boobs

15 Year Member

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Apr 25, 2019

#248

• Apr 25, 2019

• #248

I finished welding in the driver's side outer torque box in the morning. The stitch welds turned out better this time.



With that out of the way, I got started on the passenger toe board and torque box. The floor support moved a bit when I cut the spot welds from the original toe board, so I double checked to make sure that everything was still level. It's a good thing I did because the jack stand supporting the front right frame rail had shifted. I re-leveled everything before starting any welding.

The sheet metal screw trick is awesome.


I decided to cut out a larger section on this side than I did on the other. It was easier to cut out the patch.


I'm usually a quick learner. I'm glad for that.

 

horse sence

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Apr 25, 2019

#249

• Apr 25, 2019

• #249

Thats looking great

 

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02 281 GT

Agreed...My wife has great Boobs

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Apr 25, 2019

#250

• Apr 25, 2019

• #250

I had to call it a night before getting the passenger torque box welded in completely. I started having issues with the stitch welds. Tons of pop and spatter with thin, ugly welds. It was getting dark, so I decided to stop rather than try to fight the welder in the dark. I'll double check my settings and finish up tomorrow. The rest of tomorrow will be devoted to prepping the floor pan and welding that in if I have time. If not I'll get that done over the weekend or next week.

 

2Blue2

will be trying this sex one when I can find it

Mod Dude

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Apr 25, 2019

#251

• Apr 25, 2019

• #251

last batch look much improved, good job. youll be just like horse sence in no time now.

02 281 GT said:

I started having issues with the stitch welds.

Click to expand...

Welders have a duty cycle,
small budget ones have a duty cycle of 25% or less
This means it needs 75% of its time on ~ not welding to cool of the coil. This is usually based on 10 minute periods
Your probably welding faster than the machine is up to.. so 3 min of welding in 10 min and you have exceeded the 25% duty cycle.
Heat soak will lower the duty cycle even more.
Let her cool down.
It will run better beads


Keep the nice pictures coming!

 

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02 281 GT

Agreed...My wife has great Boobs

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Apr 25, 2019

#252

• Apr 25, 2019

• #252

Another welding question: how often should I change out the nozzle and tip?

Also, @horse sence I’ve seen you use an air punch like the one I have from Harbor Freight. Mine punches 3/16” holes. Is that a good size for plug welds on the floor pan? I’ve used it already, but the holes it punches seem small. Is it possible to get larger dies for tips like this one?

 

RaggedGT

Been here over a DECADE and still no CT

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Apr 26, 2019

#253

• Apr 26, 2019

• #253

02 281 GT said:

Another welding question: how often should I change out the nozzle and tip?

Also, @horse sence I’ve seen you use an air punch like the one I have from Harbor Freight. Mine punches 3/16” holes. Is that a good size for plug welds on the floor pan? I’ve used it already, but the holes it punches seem small. Is it possible to get larger dies for tips like this one?

Click to expand...

If you keep the nozzle cleaned out,it will let a long time-the one on my welders is a few years old lol-the tips are an as needed item as well

 

horse sence

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Apr 26, 2019

#254

• Apr 26, 2019

• #254

I would go back and drill the holes to 1/4 ,i do like that punch ,already wore mine out .
My welder still has the original cone but i have used a couple of tips because of burn back ,you will have this happen sometime . It is usually when the wire binds in the welder or you have a twist in the cable . About all you can do is remove the tip ,cut the wire and toss the tip and replace

 

02 281 GT

Agreed...My wife has great Boobs

15 Year Member

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Apr 26, 2019

#255

• Apr 26, 2019

• #255

RaggedGT said:

If you keep the nozzle cleaned out,it will let a long time-the one on my welders is a few years old lol-the tips are an as needed item as well

Click to expand...

horse sence said:

I would go back and drill the holes to 1/4 ,i do like that punch ,already wore mine out .
My welder still has the original cone but i have used a couple of tips because of burn back ,you will have this happen sometime . It is usually when the wire binds in the welder or you have a twist in the cable . About all you can do is remove the tip ,cut the wire and toss the tip and replace

Click to expand...

Thanks for the tips, no pun intended.

Torque boxes and toe board patches are done. I was still having issues with ugly welds on the outer torque box to frame rail. I ended up moving the ground and got better welds that way. Not sure if that was my only issue, but it worked. I wasn't getting any penetration of the frame rail before.





I know the car looks tweaked in this picture. However, I swear it's level. I double and triple-checked.



It's floor pan time. Turns out this pan DOES come with the seat platforms. I assumed it didn't since they weren't in the picture on Summit.

 

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2Blue2

will be trying this sex one when I can find it

Mod Dude

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Apr 26, 2019

#256

• Apr 26, 2019

• #256

Look at those fine torque boxes! She won't be twisting now.

 

02 281 GT

Agreed...My wife has great Boobs

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Apr 26, 2019

#257

• Apr 26, 2019

• #257

Floor pan is sitting in the car at the moment so I can trace out where I'll need to drill. There are some fitment issues, all on the passenger side. This is the off-roading damage side.






@horse sence Do you have a recommendation? Do I have larger issues to address, or should I just do what I need to make it fit? Should I fix the dented rocker before taking care of the floor pan?

 

horse sence

15 Year Member

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Apr 26, 2019

#258

• Apr 26, 2019

• #258

I have put them in by my self ,a little effort ...bunch of cussing and a few pinched fingers and no problem haha ! It goes a lot better with two people ,go through the windshield opening ,bow up in the tranny tunnel and drop the front first.

 

horse sence

15 Year Member

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Wile Coyote's stunt double

Apr 26, 2019

#259

• Apr 26, 2019

• #259

02 281 GT said:

Floor pan is sitting in the car at the moment so I can trace out where I'll need to drill. There are some fitment issues, all on the passenger side. This is the off-roading damage side.






@horse sence Do you have a recommendation? Do I have larger issues to address, or should I just do what I need to make it fit?

Click to expand...

You will have to knock it around a bit ,a few screws will pull it in place

 

horse sence

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Wile Coyote's stunt double

Apr 26, 2019

#260

• Apr 26, 2019

• #260

Screw down the outer edges first