Project IOH - 79 CJ5 Refresh - Page 3 - JeepForum.com

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post #31 of 255 Old 05-07-2012, 09:58 AM Thread Starter
2girlsAndaGuy
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1979 CJ5 
 
Join Date: Jul 2007
Location: Yakima
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rocker panel patching

Patching sheetmetal is tough work, by far the toughest welding I've had to do so (although that's not saying to much since I've only been welding for a few months or so now. )

I managed to cut out the rot on the drivers side which included a bit of the floor and some of the support structure just behind the cut out. These aren't the prettiest patches in the world but I have confidence that with a little filler and sanding you won't even be able to see them.

So I got them marked about where I wanted to cut and went to it.
driver_rocker_marked.jpg
cutting_rocker.jpg

after the sheetmetal was gone, I saw more rust behild it that needed to go as well.
driver_rocker_cut.jpg
driver_rockersupport_cut.jpg

after everything was cleaned up with a flapper I started tacking this patch in. Again let me say this was really hard for me. Burning through this stuff is super easy to do. As you can see in the last photo in this sequence the inside welds haven't been cleaned up yet. Still a bit of work to do there but I got the majority of this patch finished.
welding_rocker.jpg
driver_rocker_welded.jpg
driver_rocker_welded1.jpg
driver_rocker_floor_welded.jpg

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post #32 of 255 Old 05-07-2012, 10:04 AM Thread Starter
2girlsAndaGuy
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passanger side rocker patch

nothing earth shattering on this side either, had more rust at the floor here as well so needed to cut it out just as I did on the driver side. Made my patches using the old cut pieces as templates and started cleaning things up for welding.

passanger_rocker_marked.jpg
passanger_rocker_cut.jpg
passanger_floor_cut.jpg

again the inside of the tub isn't quite finished yet but after some grinding a bit more welding and some more grinding the inside should look fairly nice as well.
passanger_rocker_welded.jpg
passanger_rocker_floor_welded.jpg

Overall I'm quite happy with the results of these patches. They are my first attempt at doing anything like this, and I feel that although not perfect by any means they will be quite serviceable after some filler work and sanding.
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post #33 of 255 Old 05-07-2012, 11:03 AM
acgcoug
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Looks good hawk.

I'm not sure if you are using a push or pull method when welding the sheet metal, but the push method is much easier in my opinion when working with sheet metal. You are able to see your weld puddle much easier when pushing. Also, remember to move around a lot with your welds to minimize excessive heat build up.

What size wire are you using? How about wire feed speed and amp/heat setting?

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post #34 of 255 Old 05-07-2012, 11:47 AM Thread Starter
2girlsAndaGuy
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With that sheet metal I wasn't able to use any welding method other than tack...move...tack. Anything other than that and I would burn right through. There was no laying beads down on this stuff. I am running .023 wire with shielded gas, and had the wire speed set around 3 on my machine. Heat setting was at it's lowest. On the floor patches I was able to lay some beads cause I was using some thicker gauge material, but those side patches were just a cluster of tacks layed over each other.
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post #35 of 255 Old 05-07-2012, 12:19 PM
acgcoug
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Quote:
Originally Posted by littledochawk View Post
With that sheet metal I wasn't able to use any welding method other than tack...move...tack. Anything other than that and I would burn right through. There was no laying beads down on this stuff. I am running .023 wire with shielded gas, and had the wire speed set around 3 on my machine. Heat setting was at it's lowest. On the floor patches I was able to lay some beads cause I was using some thicker gauge material, but those side patches were just a cluster of tacks layed over each other.
Sounds good. You definitely have the right setup/settings.

I also found that with my tack...move...tack on my sheet metal, that my tacks came out a little better when my welding wire stuck out no more than a 1/4" from the gun tip. The arc tends to dance around less and you get a nice "eggs on a hot frying pan" sound (meaning a good tack).

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post #36 of 255 Old 05-07-2012, 12:31 PM Thread Starter
2girlsAndaGuy
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Quote:
Originally Posted by acgcoug View Post
Sounds good. You definitely have the right setup/settings.

I also found that with my tack...move...tack on my sheet metal, that my tacks came out a little better when my welding wire stuck out no more than a 1/4" from the gun tip. The arc tends to dance around less and you get a nice "eggs on a hot frying pan" sound (meaning a good tack).
I'm pretty sure I had it set up properly, I was just lacking in skill.


Here is the last of the body work that got tackled this weekend. The driverside rear corner had a nice size crack in it from who knows what, just another piece of damage to that corner from whatever the PO had hit years ago. So I spent some time shaping and beating on it. Once I was happy with it's shape it got flapped and welded up. I still have a bit of grinding to do on this one as well, but my grinding stone was on its last leg and by this point I was to lazy to put another one on.

back_corner.jpg
back_corner_bending.jpg
back_corner_shaped.jpg

back_corner_welded.jpg
back_corner_welded1.jpg
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post #37 of 255 Old 05-07-2012, 05:53 PM
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Hey LDH, that's looking good. Speaking for myself, as a beginner welder, one of the toughest things I did was grind down my welds. It seemed crazy to lay down a weld only to grind it off, so I had a tendency to leave some of the weld on top of the surface. It looks to me like you have some weld still remaining also. Don't be shy about grinding it all the way down. If you got a good tack then it is joined inside the seam. If you didn't get a good tack, you want to know about it now, and not in 8 or 9 months when a rust bubble pops up. You may have already addressed it. By the same token, the sheet metal is already thin, so be careful when you lay on the grinder.

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post #38 of 255 Old 05-07-2012, 08:02 PM Thread Starter
2girlsAndaGuy
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Quote:
Originally Posted by Skerr
Hey LDH, that's looking good. Speaking for myself, as a beginner welder, one of the toughest things I did was grind down my welds. It seemed crazy to lay down a weld only to grind it off, so I had a tendency to leave some of the weld on top of the surface. It looks to me like you have some weld still remaining also. Don't be shy about grinding it all the way down. If you got a good tack then it is joined inside the seam. If you didn't get a good tack, you want to know about it now, and not in 8 or 9 months when a rust bubble pops up. You may have already addressed it. By the same token, the sheet metal is already thin, so be careful when you lay on the grinder.
You talking about the welds on the frame or tub skerr? I don't plan to grind down the crossmember but all the sheet metal will get some more attention before I'm done with it. Thanks for the comment, it's funny that you say that because whenever I lay down a nice looking bead I'm the same way, I like to look at it not grind it off. Lol I've been struggling with just that on my fenders. Can't decide if I want to keep the welds or grind the tops smooth before paint. Thanks again for pointing me toward Jason, that worked out really well for me. Can't believe how quickly he got that crossmember to me!
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post #39 of 255 Old 05-11-2012, 09:35 AM Thread Starter
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Happy Friday

Hello and Happy friday to everyone! Hope everyone is going to have a wonderful mothersday weekend. I have the day off and sadly won't be getting much if any jeep work done today or this weekend for that matter. We have a large mothersday bbq at our house on saturday and I've got lots to get ready before tommorow.

Just incase some of you are a bit confused right now, keith made a name change for me. Here is the thread explaining it...

http://www.jeepforum.com/forum/f8/ju...ds-up-1367708/

Hope to have an update for you all later this weekend!
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post #40 of 255 Old 05-14-2012, 09:59 AM Thread Starter
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well didn't get a chance to work on the jeep at all this weekend, but I did manage to haul 4 yards of gravel and build some stairs for my deck. The bbq was a success and I managed to get the front of the house looking somewhat decent before anyone showed up. Was a long weekend working on the house, but it has been neglected for a while now.

deck.jpg
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post #41 of 255 Old 05-14-2012, 12:40 PM
jakeryii
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thats a sweet lookin patio but with the deadmans it wouldn't pass code where i live

94 ZJ 4.0, np 249 on 31x10.50s no lift
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post #42 of 255 Old 05-14-2012, 08:24 PM Thread Starter
2girlsAndaGuy
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Quote:
Originally Posted by jakeryii
thats a sweet lookin patio but with the deadmans it wouldn't pass code where i live
Thanks jake I'm happy with how it turned out, now I just need to enclose the breezeway. The nice thing about my county is that decks not exceeding 4ft in height don't require a permit.
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post #43 of 255 Old 05-15-2012, 04:49 PM
Griffen24
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Following your tread from here on out. I have a 79 CJ5 that I'm trying to build up the courage to do some body work on. It have the exact same rot on the fenders/floors that you had. Just wishing that I has some welding experience. Looks like I'll have to bring someone in for that part. Anywho, I can't wait to see how yours comes back together.
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post #44 of 255 Old 05-21-2012, 10:43 AM Thread Starter
2girlsAndaGuy
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good luck on your project griffen, won't know if you can't do the work until you at least try!
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post #45 of 255 Old 05-21-2012, 10:48 AM Thread Starter
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Ok so another weekend down and a few more items off the checklist. I got all new hoses for the fuel tank as well as upper and lower radiator hoses. After our run into town we started tearing into the tank a bit, got it removed from the skid and it looks like I'll be needing new straps. Once we got all the gas drained out of the tank we taped up the holes and pressure washed it. Haven't decided what I'm going to do with it now however, anyone got any ideas on paint choice for the tank?

tank-skid.jpg

tank-cleaned.jpg
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