welding up mirror holes

[Jeff Alton]

I am going to need to weld up the mirror holes left in my doors after removing the flag mirrors and also the hole in the fender from the antenna.

Is it better to cut the whole area away in the door where the holes are or better to patch them one at a time?

Cheers

[Porsche-O-Phile]

In the same situation here (I eventually want to lose the power flag mirrors and go back to stock chrome). I was probably going to just plug them individually, but maybe someone with actual welding skill on here can speak better to it.

[Axiom]

individual holes is better, the bigger the area, the more chance for worpage. you can cut a circle and hold it with a magnet, tack it and then move around it.

[Jeff Alton]

Pretty much what I thought, thanks for the reply Axiom. I guess try to have the small circle patch match the contour as much as possible before tacking it in? The one on the fender should be fun....

Cheers

[Axiom]

You're welcome, the antena hole is not really that bad, some guys have more difficulty with the circunference of the piece of metal and often end up overlapping it, rather than butt welding it. the metal is thick and the curve makes it even stronger, there is a O ring inside that hole, I always take it off.

Welding the gas door is a little more fun. Good luck

[Jeff Alton]

Ha, not doing the gas door.......yet.........

Cheers

[jagular911]

I would suggest using the same steel thickness and weld with a MIG (with Argon)

Be sure to cover all paint and glass that you dont want to have pitting (from the sparks)

Do not do a continuous weld around the circle-it will get too hot and you will get significant warpage. Weld 2 to 4 spots to hold it in place.

Then weld the rest of the overlap, allowing the area to cool.

If you are using oxy-acetylene, be sure to clean the flux with an acid treatment. If not, the flux will eventually cause the filler to bubble-learned this many yrs ago-you only make this mistake once.

Other thing-practice before you do this on the door.

Its not hard-it just takes a little practice

Good luck

Jon

[Jeff Alton]

I will be using my Mig, thanks for the tips guys.

Cheers

[rennch]

jeff, if you put some tape on your door, tap your donor patch into the correct shape just adjacent to the hole in the door. Put the tape next to the hole, take your donor patch and tap it so it matches the contours of the door. When you put the patch into the hole, it should be pretty close.

[Jeff Alton]

That is a good tip I had not thought of!! Thanks!

Cheers

[Jeff Alton]

Alright, I am going to start this soon. Will you guys go easy on me as I start to do some metal work? I will post pics of it, but it may not be first class work to begin with.....

Cheers

[BlueSideUp]

I'm very interested to see this process Jeff, looking forward to some pics and updates. Someone of questionable sobriety installed flag mirrors on my early car.

[haycait911]

I just bought some stuff off the mac truck, and used it. it's a clear gel that you put around the weld area, kind of a dam. and it stops the weld heat COLD! excuse the pun. cuts down on warpage. don't remember the name but will check on monday and post it. very cool stuff!

[Jeff Alton]

Uhh, yes please Don!!!!

Like I said, I am no pro with the welder, depsite my equipment!!! Any help I can get the better.

My 5 year old lays a bead almost as good as mine, but he is "advanced for his age!!!!)

Cheers

[LM3929]

Jell

the Cold stuff is available at Princess Auto $3.88 or something like that.

As far as filling the holes do them one at a time using a series of small spot welds cooling the area every 30 to 45 seconds.

It seems stupid but it works, welded an extra hole where the A/C comes inside to the side vent....but it wasn't extra.

If you need a hand call...

The guy who got you 84's frt bumper

Lorne M.

[Shaun @ Tru6]

Jeff, I've saved some scrap doors to use for this very purpose, having the curve "factory stamped" so you just need to tack it in with no metal forming. Do you want me to send you out some sheetmetal?

let me know.

S

[Jeff Alton]

Shawn, if you could, that would be perfect!!!

I am way behind on your dash, touching up the mold tomorrow, looks like christmas week before I get it out to you.....

I don't want to send the first one.....

Cheers

[Shaun @ Tru6]

OK, I'll do some cutting tonight.

To be clear, left and right doors, 3-holes worth of flag mirrors?

do not worry about the dash! I'm still sorting 40 pounds of fasteners to go to the CAD plater and may not even get to seam welding the tub until February now. And I've decided to take the entire car down to bare metal.----> no rush. maybe 2009?

[LM3929]

Jeff

I noticed on another thread that you are looking for a place to paint your car.

I'm am going to check out a small shop off Production Way in Langley that has a spot in their shop that is setup to paint in and I will see if they will rent it out to either of us.

Lorne M.

[Jeff Alton]

Lorne, wonderful! That would be great.

Cheers