Welding burn thru

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



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PostPosted: Tue Nov 16, 2021 11:47 pm
'68 Coronet R/T wrote:A lot of good information there.

Bottom line for your particular situation is to cut that portion of metal out and make a patch to weld in.

Think about your patch and the placement of your seams. Try to get the seams located where you have good access and sufficient metal for welding. Make your patches to fit nice and snug into the openings as well.

I found it much easier to learn proper welder setting by practicing on odd pieces of metal.
Start with the recommended settings for your welder on that thickness of metal and see what you get. A porous mound of metal may require more heat or less wire feed.

There are videos out there that go into detail on setting up a MIG.

I've already have my donor patch. Just need the time to install it.



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PostPosted: Thu Dec 02, 2021 10:41 am
Well its been a while How did it turn out?
Dennis Barnett
A&P Mechanic, FCC General radio Telephone Operator
Line Maintenance A&P Mechanic and MOC Tech specialist.



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PostPosted: Fri Dec 03, 2021 12:43 am
20211202_212530[1].jpg
Well I wish I had more time! Anyways, I'm showing two pics. One of the donor piece. The other I've marked with thick black line where I think I will cut out. I am no expert. I appreciate any advice. Thanks.
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PostPosted: Fri Dec 03, 2021 8:19 am
Best advice I can give it to cut it out, with an extra margin of metal, around 1/4-1/2 inch. Then sneak up onto it with hand snips. Maybe final "shaving" to get it perfect, with a 2 or 3 inch sanding disc on an angle grinder, or hand file.



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PostPosted: Fri Dec 03, 2021 9:10 pm
I like body saws such as this:
https://www.harborfreight.com/high-spee ... uDEALw_wcB

Then over lap both the patch panel and the panel needing repair, Then cut both at same time with thinnest cutting blade available to get perfect cut line that matches.Then Try to get gap to zero gap OR as close as possible by filing the cut line using a file as Necessary. When I use a lot of patients I can get close to zero gap. then Tig weld or Gas weld a fusion weld. with zero filler rod is goal. when done correctly with a Tig welder you have perfect repair requiring little to no hammer and dolly work with little to no filler required to hide the repair.

A Mig can be used but keep the welds to a Zap zap zap a million times deal Not really welding in my opinion. Puts more heat into panel requires more hammer and dolley work over heats panel and bead is harder than Gas or Tig welding.
Dennis Barnett
A&P Mechanic, FCC General radio Telephone Operator
Line Maintenance A&P Mechanic and MOC Tech specialist.



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PostPosted: Sat Dec 04, 2021 11:57 am
It's going to be mig and hopefully I won't burn thru this time....
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