Progress Thread The "grátis" 1966 Coupe project

horse sence

That $5 hooker turn out to be a guy
Mod Dude
Nov 29, 1999
8,589
2,718
233
Wile Coyote's stunt double
Use large self drilling screws to pull panels tight together like on the bottom of the torque box ,remove the screws after welding and fill in the holes .you can put the screws right through a couple of your plug weld holes and they will fill in when you weld
 
  • Sponsors (?)


2Blue2

Advanced Member
Mar 5, 2019
546
278
73
52
Oahu
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.
 
  • Agree
Reactions: Davedacarpainter

02 281 GT

Agreed...My wife has great Boobs
10 Year Member
Feb 3, 2009
1,675
959
164
Wichita Falls, TX
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.
 

horse sence

That $5 hooker turn out to be a guy
Mod Dude
Nov 29, 1999
8,589
2,718
233
Wile Coyote's stunt double
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
 

02 281 GT

Agreed...My wife has great Boobs
10 Year Member
Feb 3, 2009
1,675
959
164
Wichita Falls, TX
I finished welding in the driver's side outer torque box in the morning. The stitch welds turned out better this time.
JF0jao0.jpg

SY3dAb5.jpg


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.
Vw68UQp.jpg


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.
OVLj2eo.jpg


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

02 281 GT

Agreed...My wife has great Boobs
10 Year Member
Feb 3, 2009
1,675
959
164
Wichita Falls, TX
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

Advanced Member
Mar 5, 2019
546
278
73
52
Oahu
last batch look much improved, good job. youll be just like horse sence in no time now.:rolleyes:



I started having issues with the stitch welds.
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!:)
 
  • Like
Reactions: 02 281 GT

02 281 GT

Agreed...My wife has great Boobs
10 Year Member
Feb 3, 2009
1,675
959
164
Wichita Falls, TX
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

check back later..
Mod Dude
Jul 20, 2014
4,356
2,868
193
34
Taylorsville ky
www.stangnet.com
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?
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

That $5 hooker turn out to be a guy
Mod Dude
Nov 29, 1999
8,589
2,718
233
Wile Coyote's stunt double
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
10 Year Member
Feb 3, 2009
1,675
959
164
Wichita Falls, TX
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
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
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.
OSjl0aa.jpg

KY4ZM5x.jpg

mVEcNnV.jpg

VeR92J9.jpg


I know the car looks tweaked in this picture. However, I swear it's level. I double and triple-checked.
ru5QI45.jpg

HogK9AW.jpg


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.
NBqcS9B.jpg

UFDyGLb.jpg
 

02 281 GT

Agreed...My wife has great Boobs
10 Year Member
Feb 3, 2009
1,675
959
164
Wichita Falls, TX
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.
9PyPIoV.jpg

eWGBBCZ.jpg

6icFTv7.jpg

GA1z6sr.jpg

a8ootoL.jpg


@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

That $5 hooker turn out to be a guy
Mod Dude
Nov 29, 1999
8,589
2,718
233
Wile Coyote's stunt double
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

That $5 hooker turn out to be a guy
Mod Dude
Nov 29, 1999
8,589
2,718
233
Wile Coyote's stunt double
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.
9PyPIoV.jpg

eWGBBCZ.jpg

6icFTv7.jpg

GA1z6sr.jpg

a8ootoL.jpg


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