Project Update - learning to weld RSR style

cali74 · 02-10-2006, 04:52 PM

So I got a welder and plasma cutter, and after some good advice on technique from Doug (DW SD) I was off to do battle on the car...

(don't blame Doug if the welds aren't clean, they were my own painful lessons!!!)

I did the shock tower supports after putting in strips flat where the crossmember meets the body. I also put triangles under the front edge of the crossmember thanks to the thread Tyson posted earlier on supports. The front wheel well had a NASTY looking hole that had been cut for A/C lines that was all narly on the edges and bent up. I fit a piece in, welded the hell out of it, then grinded it flat so it'd look decent after paint.

Next up is the front pan, I'm only halfway there on that project...

cali74 · 02-10-2006, 04:53 PM

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cali74 · 02-10-2006, 04:54 PM

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cali74 · 02-10-2006, 04:55 PM

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cali74 · 02-10-2006, 04:56 PM

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cali74 · 02-10-2006, 04:57 PM

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DW SD · 02-10-2006, 05:13 PM

Looks like a VERY nice job! Congrats! Nice clean welds from my vantage point!

Sure was FUN playing with the plasma cutter the other day! Just don't get a digit or another extremity in the way of that puppy!!

Good work!
On deck circle: paint for the engine compartment and your nuclear certification (welding)!!
Baby steps, mi amigo!

Doug

cali74 · 02-10-2006, 05:25 PM

on deck circle...just no on deck changing :-)

Thanks for the kind words - welding is fun, and I'm definately proof that with the right tool, anyone can weld.

Note to other pelicanites - close proximity to miller tools may cause increased desire to upgrade and spend money :-P

Jeff Alton · 02-10-2006, 07:02 PM

Nice job on the welding, especially if you are new to it! Looks great. That is on my list of things to do next week. What guage metal did you use and what machine are you using to weld?

Once again, nice job!

Cheers

DonDavis · DonDavis's Garage

Very very cool!! I need to get a welder. There have been way too many times I've thought "Oh, I could just weld that up."

cali74 · 02-10-2006, 07:21 PM

Thanks Jeff :-)

I used 11 gauge steel (=1/8") after Tyson mentioned that's what he used (thanks Tyson for that great thread!). The A/C hole I used 18 gauge steel which was pretty close (a little thicker prolly) to the inner front fender wall.

The welder is a Millermatic 175 with infinate adjustment on wire speed and voltage. It runs off 220 power, and I used .023 wire for all this welding. Definately the infinate adjustment is KEY for someone like me who's never welded before. I don't know how to compensate as well as an experienced person if the settings are too far off (it seems easier to dial in the settings properly then compensate for incorrect settings).

Good luck on yours! If you're doing the shock towers like I did, make templates out of paper or cardboard and cut the metal triangles with straight edges on the shock tower side.

Then hold the metal piece in position and mark it a little with a sharpie to indicate where to grind it down. Use a bench grinder to shape the triangle's shock tower edge a little at a time until it fits really well. Take a LONG time to fit the trangles just right and the welding will be easy and come out better.

Don't skimp on the fitment, it's way harder to make up gaps with welding than it is to take your time on the template.

Oh, and when you get tired of welding, go drag knee for a while, and you'll be cured :-)

911pcars · 02-10-2006, 08:11 PM

Is the weld bead only on the facing side? Is there access to lay a bead on the back side? Nice job though.

Sherwood

jtratza · 02-10-2006, 08:21 PM

You must be the only one that thinks the welds don't look clean. Not much looks better than shiny metal work on a 911. Well maybe Zoanas' avatar but not much else.

cali74 · 02-10-2006, 08:25 PM

Sherwood - the weld is only on the facing side on mine. I went and checked and it looks like there are a few sections where you might be able to fit the gun on the backside. There wouldn't be any visibility at all - welding blind. Maybe someone in the know could give an idea if it's needed. If so I can go try and give you the results!

Jeff Alton · 02-10-2006, 08:34 PM

Cool, I too have a 175, great welder. Thanks for the additional info!

Cheers

ZOA NOM · ZOA NOM's Garage

Quote:

Originally posted by jtratza
You must be the only one that thinks the welds don't look clean. Not much looks better than shiny metal work on a 911. Well maybe Zoanas' avatar but not much else.

Here, for comparison...

jtratza · 02-11-2006, 06:15 AM

Yup. Zoanas wins. Sorry.

captainrb · 02-11-2006, 07:19 AM

Great job !! You certainly spent allot of time grinding and prepping the area. As with most projects prep is the key to success.Was the reason you made this modification.You have installed coil over shocks ? I've installed them (coil overs)on my 73' and plan a similar modification in the spring. Also is there room behind the plates to weld on the back side

Zeke · 02-11-2006, 07:28 AM

Quote:

Originally posted by cali74

The welder is a Millermatic 175 with infinate adjustment on wire speed and voltage. It runs off 220 power, and I used .023 wire for all this welding. Definately the infinate adjustment is KEY for someone like me who's never welded before. I don't know how to compensate as well as an experienced person if the settings are too far off (it seems easier to dial in the settings properly then compensate for incorrect settings.

You got that right. But, to reduce voltage, all you have to do is lean the tip over some more and increase the stick out. That should help bridge the gap between fixed settings. However, talk is cheap.

Tom '74 911 · 02-11-2006, 10:00 AM

cali74 - that is a great job. How did you get your engine bay down to (very clean looking) bare metal? Did you use paint stripper/grinder etc.... I'd like to know!
Thanks,
Tom