Replacing bed sides

More of an art than a science - discuss metalworking and welding here.



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PostPosted: Tue Sep 22, 2015 3:05 pm
ok, so i have a 2005 dodge ram that I've been restoring. bedsides are starting to rust out and thinking about replacing. Ok, so I've read up on how to drill out spot welds with blair drill bit. What would one use to grind out the rest? I have a corded angle grinder but my air compressor is pretty small. Also can one paint the outside of panel before spot welding it back in?



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PostPosted: Wed Sep 23, 2015 3:45 pm
I've been doing rust repair on my samurai.

My thoughts;
The more tools that you have at your disposal, the better. You will find a way to use them all, as the job at the moment dictates. I found air grinders useful, with the thin 3" cut off wheels, and using the 1/4" carbide die grinding bits also. I also used an autobody panel reciprocating tool to cut out rusty metal in tight spots, as well as air chisel, needle scaler, air nibbler and an air flanging tools. Like I said, if you have the tools, you will use them all.

Maybe buy the air tools you think you need and rent a bigger compressor? Or, use the compressor you have and go slow, letting the pressure catch up as you continue to work.

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PostPosted: Wed Sep 23, 2015 4:42 pm
I would not suggest painting till after. You will be burning areas and have a good chance of causing additional damage and warping that you would just need to repair and repaint again after.. automotive paint is way to expensive to deal with repaints. you can get away with an electric grinder for some of it, but be careful if you don't have one with variable speed as sheet metal is thin and you can burn thru both layers fairly quickly with a high speed electric grinder



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PostPosted: Sat Sep 26, 2015 2:53 am
I should start by saying that I am not a professional! I am a carpenter and mechanical hobbiest with a short attention span so I decided to try body work and metal shaping. So take my advice for what it's worth. I also have a bit of a tool fetish and this may be where I have reasonable advice. Body work is pretty slow without a big comressor and painting is impossible. If you have the time to take off work then maybe renting is an option but I don't get to the garage every day. Between work, kids and women I'm lucky to get a few hours a week. Renting tools just won't work for me. I got a few air tools and tried to run them on my "big" 20 gallon compressor but it really just wasn't practical. So save up and get a good compressor. I eventually found a 400 gallon on Craigslist for a few hundred bucks. Also most of the stuff that I have gotten at harbor freight has been disappointing. The stuff that I have been given or found on Craigslist is mostly somewhat worn quality stuff. Way better than the harbor freight stuff. I got a few of the husky brand air tools from home depot. Not as cheap as harbor freight but way better. I would consider that stuff the bottom end of acceptability. Really the big ticket items are where quality matters the most as a disappointment with those is a much bigger waste of money. Get a good compressor and a good welder. Get used quality over new cheap whenever possible. The welding supply store (where you get gas, not home Depot or tractor supply) and the auto paint Store have been good sources of advice when they aren't busy. If they're bored they will talk your ear off. If they're busy then they don't want to deal with you. Know the difference and listen carefully as the guys who talk the most are not always the guys that you should be listening to. Good luck! I obviously talk too much!



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PostPosted: Tue Sep 29, 2015 4:04 pm
Don't paint till your done!

Read a bit more on this web sight completed and in progress projects youll get the idea.

Buy the biggest air compressor you can afford but it wont be big enough till you get into a true 7-10hp machines. air tools such as angle die grinders even if cheap ones from Harbor freight are your friends just buy a few at less than $20 there not bad they will last a little while before they crap out.
Dennis B.
A&P Mechanic, FCC General radio Telephone Operator
Line Maintenance A&P Mechanic and MOC Tech specialist.

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