405 Rust

evilally · Post by **evilally** » 21 Jun 2010, 22:19

Cheers guys, I think i'll get one of those cool masks ordered up

I have also "acquired" the Haynes Welding Manual.

addo · Post by **addo** » 21 Jun 2010, 23:18

One thing when teaching yourself welding, is to try breaking those "dummy" pieces you've welded up. Use brute force, and see where the parts yield - it will potentially reveal flaws in technique.

citronut · Post by **citronut** » 22 Jun 2010, 08:52

you must achive full penatration

regards malcolm

evilally · Post by **evilally** » 29 Jun 2010, 22:08

Finally got around to playing with my new welder this evening. I managed to weld 2 vegetable oil tins together:

For some reason I find this hilarious. I've got enough of these tins to build a tower to the moon

Anyway, my welding is utter crap, lots more practise required.

addo · Post by **addo** » 30 Jun 2010, 01:09

You could build an upscale version of those "beer can boats" famous in the seventies.

Overall, the general idea with making stuff in your yard, is to create things too large for being moved easily in one piece.

citronut · Post by **citronut** » 30 Jun 2010, 08:17

looking at those weld's you need a bit more penatration, as it dosen't look like you have blown any holes in those can's yet, and those welds look like there just on the surface,

cut one open to see how deap the welds have penatrated

if you can can weld those tinny's you will make a good dersh welder,

regards malcolm

evilally · Post by **evilally** » 26 Jul 2010, 19:59

Can anyone give any advice on removing the outer sill?

addo · Post by **addo** » 26 Jul 2010, 22:52

Have you bought the new piece yet?

Cutting is best done "cold" - ie, using a reciprocating saw - as it doesn't embed carbon smut into the cut edge so badly. Failing that, try a thin cutoff wheel in a flex shaft tool or die grinder.

Spot welds are drilled out with a Wurth spot drilling bit or similar - it helps to lightly centre pop the weld first.

For that matter, get to know your Wurth rep as they do a couple of ripper primers - Acid #8 and also another weld-through zinc primer. Buy the 100g tube of copper lube while you're at it (immensely superior to any other copper grease).

evilally · Post by **evilally** » 09 Sep 2010, 20:28

Update to this at last!

It failed on the rust on the sill, no other advisories. I set about chopping out the rust, lots of it:

I ended up chopping out a lot more than that

Took me ages, and it looks very frankensteinish, but it's strong which is all I need:

I'll leave it untreated until after it's restest. I plan to paint it over and seal it with some liquid rubber, much like what Peugeot used. I was thinking Ronseal roof rubber?

Can someone advise the best way of stopping it rotting from the inside out?

addo · Post by **addo** » 09 Sep 2010, 23:06

Waxoyl type stuff is good for the box sections.

Ideally, a "weld-through" primer is applied to the metal on both sides before it's welded in.

Post by **RichardW** » 10 Sep 2010, 09:04

Funny (?!?) how a small hole turns into a 'kin big one once you clean it up! Looking good though Ally - but from that picture, I would say you are not really using enough current on the weld - it looks to be standing a bit proud on the the surface.... Hope you get a ticket on it!