My sheetmetal work

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Thought I would post up some pics from this mornings work.  I am currently replacing rusted metal on my 89 Wrangler.The shots are not that great but you get the idea of what I am doing.   The tub is 18G and all I could get my hands on is 16G but it worked out.   These were done with mig and C25 Gas.  The only thing I think may be a problem is that there is just slightly too much sheet metal in the fill so it bows a little.   I will pull it in when I weld in the new floor pan.  Those pics to follow this week.Before Pic:And the new:Come try it out and stay a while.
Reply:Looks pretty good. If the penetration is good you should be able to grind the welds completely down and work the metal to get it straight. Not sure how your welding process went but if you pein the the welds during the welding process at the right time, you can get the the finished panel pretty flat. wrapage is aways a problem when welding sheet metal. Also I keep a cold wet rage to cool the welds as I am going the make the metal wrap the way I want. It is an art so try a practice piece or just try peining and using the cold wet rage and see how the metal reacts. You will get the hang of it quick enough. One word of advise. Never weld continuously. Only weld an inch or so than move to a different place. If you try to weld on a continuous weld, the wrapage can get out of hand. The wrapage will compound on itself causing major wrapage.Hope this helps and keep us up to date with pics.Have fun. Miller DVI2Lincoln Precision Tig 225Thermodynamics Cutmaster 38Everything else needed.
Reply:Looks pretty dang good to me, brings back good(?) memories of replacing pieces of my rusted-out 89 daytona floor.Nice work !- John
Reply:Originally Posted by jamlitLooks pretty good. If the penetration is good you should be able to grind the welds completely down and work the metal to get it straight. Not sure how your welding process went but if you pein the the welds during the welding process at the right time, you can get the the finished panel pretty flat. wrapage is aways a problem when welding sheet metal. Also I keep a cold wet rage to cool the welds as I am going the make the metal wrap the way I want. It is an art so try a practice piece or just try peining and using the cold wet rage and see how the metal reacts. You will get the hang of it quick enough. One word of advise. Never weld continuously. Only weld an inch or so than move to a different place. If you try to weld on a continuous weld, the wrapage can get out of hand. The wrapage will compound on itself causing major wrapage.Hope this helps and keep us up to date with pics.Have fun.
Reply:Originally Posted by rustywranglerThanx man,  I will try the wet rag idea.  I only went about 1/2" at a time a few inches apart and waited a min or two to let it cool.Peining??  What is this method?   Honestly don't know....
Reply:Thanx man,  I actually found some info online and found it in my welding text book in automotive section, who'd a thought  Come try it out and stay a while.
Reply:cool, keep us posted.Miller DVI2Lincoln Precision Tig 225Thermodynamics Cutmaster 38Everything else needed.
Reply:From what I can tell from the back side, these welds are deep enough so that I can grind them flush but I will definatly give the"peining" a shot.  Come try it out and stay a while.
Reply:wow where do you live to get that kind of rust in an 89 jeep,im in autobody and i live in texas but i sure dont see rust like that around here,at first i thought it was bullet holes lol
Reply:Originally Posted by paintmanwow where do you live to get that kind of rust in an 89 jeep,im in autobody and i live in texas but i sure dont see rust like that around here,at first i thought it was bullet holes lol
Reply:I would like to see you find a pirstine 89 jeep in new york state.Nice work.  DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Originally Posted by paintmanwow where do you live to get that kind of rust in an 89 jeep,im in autobody and i live in texas but i sure dont see rust like that around here,at first i thought it was bullet holes lol
Reply:Originally Posted by David RI would like to see you find a pirstine 89 jeep in new york state.Nice work.  David
Reply:we got snow here in texas once  lol
Reply:Some more work done today.A few weld pics:        Rustoliumed the pass foot well.  And last but not least, what I get to work on next: Come try it out and stay a while.
Reply:wow, you have a fun task ahead of you! say, can you go to a junk yard and find a wrecked jeep with THAT floor section in tact?  Then, cut and paste the good parts?  (I have a feeling that is the first place to rust in old jeeps... like the wheel wells on my Bronco.)
Reply:Originally Posted by HokieEdwow, you have a fun task ahead of you! say, can you go to a junk yard and find a wrecked jeep with THAT floor section in tact?  Then, cut and paste the good parts?  (I have a feeling that is the first place to rust in old jeeps... like the wheel wells on my Bronco.)
Reply:Down here in VA guys part out Jeeps and sell decent tubs all the time.  I replaced a floor pan in my YJ but nothing like what your doing.  I think I'd go for another tub...but, hey!  It's good welding practice!  MM175 MIGCutmaster 38 PlasmaCraftsman 30gal compressor4x6 HF bandsaw1hp HF floor drill pressRyobi Cutoff SawAssorted grindersNot enough time
Reply:Originally Posted by MUDBUGDown here in VA guys part out Jeeps and sell decent tubs all the time.  I replaced a floor pan in my YJ but nothing like what your doing.  I think I'd go for another tub...but, hey!  It's good welding practice!
Reply:http://www.novajeepers.com/index.php...&highlight=tubHere's one that you could get for a decent price...less than $500 anyway.  Don't know if it's still available but you can search around on this site for some jeeps being parted out.MM175 MIGCutmaster 38 PlasmaCraftsman 30gal compressor4x6 HF bandsaw1hp HF floor drill pressRyobi Cutoff SawAssorted grindersNot enough time
Reply:Wow, rusty. Looks like you are getting along great and doing a good job. I like the fact that the panels you made look great and fit in nicely. I would have picked up the bead roller from Harbor Freight and rolled in the beads to look factor. It does a pretty good job and does make for a nice factory affect. Keep up the great work and make sure to post some pics of the completed job.Miller DVI2Lincoln Precision Tig 225Thermodynamics Cutmaster 38Everything else needed.
Reply:Looks like we got a body panel man in the making! Nice work, looks like you are coming along nicely.  Wish you were closer.  I had a tub I'd give away just to quit looking at it behind my shop.  My best friend is a BIG jeep guy.  Constantly rebuilding and selling them.  I think he likes working on them more than riding in them.  We took two and made one, and stretched it into a four door about a year ago, and we had this tub for panels if we needed it which we didn't.  All that work and he sold it in three months!  I almost had a stroke!  anyway keep up the nice work.  I'm ready to see some paint shining on that thing!  keep the pics coming!  ~JacksonI'm a Lover, Fighter, Wild horse Rider, and a pretty good welding man......
Reply:when we replaced the floor pans in our 77 bronco we bought a kit with the floor pans and just welded them into place and it cost next to nothing i think you can do the same for a jeep there much more common than classic bronco's.
Reply:Looks good RustyWrangler. I'm interested to see how the floor pans look after you grind down the welds. I need to replace the floor pans in my 75 Bronco. Also, how did the rocker panel turn out? Did you clean up those welds yet? CarlLincoln AC/DC 225/125 Stick Linde HDA-300 MillerMatic DVI MIG Miller Dynasty 200DX Hypertherm Powermax 1000
Reply:Originally Posted by allengradingwhen we replaced the floor pans in our 77 bronco we bought a kit with the floor pans and just welded them into place and it cost next to nothing i think you can do the same for a jeep there much more common than classic bronco's.Originally Posted by jamlitWow, rusty. Looks like you are getting along great and doing a good job. I like the fact that the panels you made look great and fit in nicely. I would have picked up the bead roller from Harbor Freight and rolled in the beads to look factor. It does a pretty good job and does make for a nice factory affect. Keep up the great work and make sure to post some pics of the completed job.
Reply:A little preventative maint. done to keep the rust back after grinding and cleaning.  Will have more weld pics later today.Come try it out and stay a while.
Reply:Well, Finally, here is an update. I spent some more time on the jeep the past few days here and there. This morning I got alot acomplished. I will start with the pics.    I left the curve of the wheel well in place as a reference. I will remove that when I get the panels mocked up. And now for the final prep before new pieces are made up.    Last edited by rustywrangler; 09-23-2007 at 08:11 PM.Come try it out and stay a while.
Reply:Had to do a little renforcement of the underside crossmember.  I learned the term roset weld today. Had to attach the crossmembers to the sheetmetal.   Got the rear upper support in.   Pay no attention to the small backer parts. Those are already off, I needed something to weld to because I created a larger gap than I wanted to fill. More to come people. Feelin good with this weather. Gonna have tons done this week.Come try it out and stay a while.
Reply:Started preping my replacement fenders and got a coat of primer on them. I found a small rust area that I will take care of in the AM. It was under some bubbling paint. That rust spot looks oddly familiar (current fender)Come try it out and stay a while.
Reply:hey rusty you are from the same area i am from. i still have a brother that lives there. we lived in oswego county ny just right beside you. we actually would get more snow on a yearly basis than syracuse because we lived in the tug hill plateau. It was all over the news this past winter they got something like 100 inches of snow in one week.
Reply:Originally Posted by down19992000hey rusty you are from the same area i am from. i still have a brother that lives there. we lived in oswego county ny just right beside you. we actually would get more snow on a yearly basis than syracuse because we lived in the tug hill plateau. It was all over the news this past winter they got something like 100 inches of snow in one week.
Reply:Got a little bit more done today. Finally have a complete floor with spot welds to connect the crossmember underneith.   I also got the seatbelt mount started.  A dry fit, still needs some tweeking.  Any advice for this area will help. I plan to just box that in like it was from the factory.Come try it out and stay a while.
Reply:Man I hate rust repair. You're doing a great job of it though.Lincoln PowerMIG 215XTLincoln Precision TIG 225Hypertherm 300
Reply:Originally Posted by Twisted MinisMan I hate rust repair. You're doing a great job of it though.
Reply:I have not updated in a while but here is the latest. The jeep has a new home in my aunts 4 car garage:And how far I got the last time I was up there:More to follow after January. My son is due next week. Gonna be fun with 2 kids now LOL.Come try it out and stay a while.
Reply:Cool Rusty. Hopefully you will be driving it by this summer.Is your aunt's garage very far from your place ?Miller DVI2Lincoln Precision Tig 225Thermodynamics Cutmaster 38Everything else needed.
Reply:Originally Posted by jamlitCool Rusty. Hopefully you will be driving it by this summer.Is your aunt's garage very far from your place ?
Reply:Originally Posted by rustywrangler30 min but she provides daycare for the rugrat so it works out.
Reply:Well I finally got some time to do some work on the Heep yesterday. Here are a few pics of what we did. I got the windsheild completely off and the hinges. LOL I know where my dash leak is now.   We got the dash unbolted and pulled back a bit (time to do a small speaker modification. For those interested, here is how accessable the drivers side speaker is with the windsheild folded and the stearing column bezel removed. You can pull it back a good 4"-5". (Ignore the patented dash support lol)  We also did a little fender work LOL Replacement fender (thanx again Sentinal02)  ANd the end result for the afternoon:   And finally, my personal assistant (My brother) at work....Come try it out and stay a while.
Reply:Lookin good!
Reply:On Body repairs i use oxy-ace for neat outcome... you'll just have to hammer a bit for some adjustments... But bro it looks nice....
Reply:Originally Posted by nse_joshuaOn Body repairs i use oxy-ace for neat outcome... you'll just have to hammer a bit for some adjustments... But bro it looks nice....
Reply:A few updates from the last month or so:3/9/08 Some prep but the big one is, the drivers side floor pan is in and done. I do not have final pics but here are some of the midday work. Pop rivits used to put panels in place After welding in, yes I know there are some small holes but they are now filled: Preped and painted drivers side hinge area: My Bro also worked on the front bumper area and cleaned up alot of the PO's "gobily gook" welds. Gave it a coat of paint as well. Gonna have to work on the drivers side frame rail end, a bit chewed up: And we test fitted the TJ front bumper I picked up:  All in all, it was a good day. Got outta the house for a while and enjoyed hangin with my Bro.NEXT POST......Come try it out and stay a while.
Reply:Finally finished up the drivers side floor pan area.     Alot more to come, I just forgot to take pics. I built up a custom batt tray and fuse block mount. It will also include all or my relays for various accessories. The pass side fender is now completely installed and the drivers side is off.NEXT POST......Come try it out and stay a while.
Reply:From yesterday:Got some more work done yesterday. I started the pass side seat belt area. Prior to starting the work: And after excising the rust demons:YES THOSE ARE THE UPPER AND LOWER SEAT BELT MOUNTS   That would have sucked the big one in a wreck.  BUT, hey, at least this side was still attached to the body, kinda. More to come tomorrow. I have 3 whole days this week planned out to get things done. THen I start bolting stuff on. -Rusty :tea:Last edited by rustywrangler; 03-28-2008 at 09:41 AM.Come try it out and stay a while.
Reply:Looking good. Keep up the pace man as the warmer weather is going to come some time soon,, I hope.Miller DVI2Lincoln Precision Tig 225Thermodynamics Cutmaster 38Everything else needed.
Reply:Originally Posted by jamlitLooking good. Keep up the pace man as the warmer weather is going to come some time soon,, I hope.
Reply:Originally Posted by rustywrangler  Tell me about it.  Yesterday worked with the garage open and a flannel on, cracked open the grill for some burgers and today I get this.
Reply:looks great, you got your work cut out for you though