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Thread: Attempting to weld a 1/4 inch panel gap

  1. #1
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    Attempting to weld a 1/4 inch panel gap

    A new firewall would have been better, but I'm going to try to weld the huge piece someone hacked out of this one. The panel gap is too wide to butt weld, so I'm using 1/8in tig rod as a filler. Taking short pieces bent to follow the contours, and tacking in place at this stage. I think it will work. A couple sections are too wide that will need a small piece of sheet metal. It will blend right in with all the other hack repairs done 40 years ago.IMG_0229.jpgIMG_0231.jpgIMG_0233.jpg
    Last edited by 55 Rescue Dog; 09-15-2016 at 06:07 AM.

  2. #2
    Registered Member MP&C's Avatar
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    You're likely looking at quite a bit of heat and distortion filling in that much width. Another option is to weld a strip of sheet metal around the perimeter of the inner piece, then planish when complete to remove distortion. Now trim to fit the hole, weld, planish, etc. until complete.

    And this isn't to say your method won't work. But another may be easier/quicker.
    Last edited by MP&C; 09-16-2016 at 05:47 AM.
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    Good advice Robert.

    I've had to use that method when I've made an error and trimmed too much. I cut a 3/4" - 1" strip and weld it to the piece that I can weld at the bench. Then planish and grind, and finally do a new trimming job. The wider strip keeps it from getting too hot while welding it. The planished and metal finished weld means the panel will behave like normal sheet metal when you weld it in place.

  4. #4
    Registered Member NickP's Avatar
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    Quote Originally Posted by 55 Rescue Dog View Post
    A new firewall would have been better, but I'm going to try to weld the huge piece someone hacked out of this one. The panel gap is too wide to butt weld, so I'm using 1/8in tig rod as a filler. Taking short pieces bent to follow the contours, and tacking in place at this stage. I think it will work. A couple sections are too wide that will need a small piece of sheet metal. It will blend right in with all the other hack repairs done 40 years ago.IMG_0229.jpgIMG_0231.jpgIMG_0233.jpg
    Almost seems like it would be simpler to get a replacement firewall. Less work 4 certain.

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    However you decide to do it, you won't have to worry too much about distortion, not like a body panel anyway. First of all there is a lot of shape there which will reduce it, and the engine will cover all most all of it anyway.

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    Finally got it back in place after too many windy days to weld outside, and other stuff to do. Far from perfect, but blasted, a little filler, paint, and an engine hiding,IMG_0311.JPG it will have to do. Seam sealer will handle the backside under carpet, etc. Emptied out an old can of paint right over the dirt for now.IMG_0312.JPG
    Last edited by 55 Rescue Dog; 10-20-2016 at 05:15 AM.

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    Registered Member NickP's Avatar
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