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crackerhigher03 · 01-11-2010, 01:17 PM

Ok. I have another question on welding in new sheet metal. I am usings a 90 amp flux core harbor frieght welder using .030 flux wire. I had grinded down the rust to bare metal and there was some holes in some places and the metal was kinda thin. I decided to cut out the thin piece with the holes in it and fit another piece of sheet metal then try to tack in. I noticed when I grinded down the welds that that there was some tiny pin holes in the welds and when trying to seal those that it would blow a hole right the metal. Would like to get a decent MIG with gas to do cleaner welds but its not in the budget now. I have had a few ideas cross my mind such as either brazing these panels in oxy/acy or either just fiber glassing over the ruff areas and sanding it down smooth. This will not be a show truck but I also do not want to open the door and a rocker panel fall off one day.

Does anyone have any tips and suggestions for doing this?

01-11-2010, 01:17 PM	#5
crackerhigher03 Registered User Join Date: Jan 2010 Location: North Florida Posts: 6	Re: 1984 Chevy Custom Deluxe Ok. I have another question on welding in new sheet metal. I am usings a 90 amp flux core harbor frieght welder using .030 flux wire. I had grinded down the rust to bare metal and there was some holes in some places and the metal was kinda thin. I decided to cut out the thin piece with the holes in it and fit another piece of sheet metal then try to tack in. I noticed when I grinded down the welds that that there was some tiny pin holes in the welds and when trying to seal those that it would blow a hole right the metal. Would like to get a decent MIG with gas to do cleaner welds but its not in the budget now. I have had a few ideas cross my mind such as either brazing these panels in oxy/acy or either just fiber glassing over the ruff areas and sanding it down smooth. This will not be a show truck but I also do not want to open the door and a rocker panel fall off one day. Does anyone have any tips and suggestions for doing this?