With the damaged areas on the door prepped and sanded down to the bare metal, serious repair can begin with use of welding equipment. After welding, the damaged areas are covered and smoothed over with body filler. Welding Tips
Safety Alert: Welding can be extremely dangerous if not done properly, and if a number of critical safety precautions are not followed. Undertake welding only if you have had proper instruction. Safety Alert: Always wear eye protection -- goggles or safety glasses -- when using any power tools.
- For our repair, we used a MIG wire-feed welder (figure A). Welders are available from equipment rental stores. Be certain to follow all directions and safety precautions that come with the equipment. Welders have a number of settings that vary according to the job. Lower-voltage settings should be used for thinner metal. For our repair, the voltage was set to "1."
- The welding mechanism uses a wire that extends from the end of a nozzle. A trigger activates the end of the wire and introduces a flammable gas to create a clean weld. "MIG" stand for "metal inert gas." Most professionals use gas welders because they produce such a clean weld.
- Important: Be certain that the welder's ground clamp is connected to a clean metal surface (figure B) before you begin.
- Safety Alert: It is imperative to put on a welding helmet with a suitable visor, and welding gloves (figure C) before you begin work. There are different visor lenses depending on the type of welding being done. Make sure that you have the appropriate lens. Welding while using the wrong lens could result in damage to your eyes.
- Safety Alert: It's a good idea to have a spray-bottle filled with water nearby when welding in case something ignites from a welding spark.
- At the start of the weld, the wire at the tip of the welder should protrude about 1/4-inch beyond the end of the nozzle (figure D). Once you've established your arc, you can go to a longer "stick-out" to fill larger gaps.
- Tip: Be aware of the distance from your work surface and how quickly you are welding. The rate at which you move along the joint is called "travel speed." It may be necessary to slow down or back off slightly on your welds (figure E).
- Once you're finished welding, use the disc grinder to smooth the welded area (figure F).
Body-Filler Tips
With welding and grinding done, the next phase of the repair is the use of body filler. We used two typed of filler on this repair: fiberglass filler for a base coat and plastic filler for a smooth, finishing coat. Body fillers are available from auto supply stores. Follow the instructions that come with the filler that you select. Tip: Be careful when adding hardener to your filler. The more use, the faster the hardening process. If you add too much, the filler may harden before you can apply it. - Try to keep the first coat of fiberglass filler as smooth as possible (figure G). This will mean less excess will need to be sanded off later. Make certain that you fill any small crevices of the repair area.
- The filler will harden quickly. When it does, sand it smooth using 40- to 80-grit sandpaper and a sanding block (figure H).
- Apply the plastic filler in the same manner (figure I), keeping the application as smooth as possible.
- Once the plastic filler dries, sand it smooth using 80-grit sandpaper.
In the segment that follows, the repair continues on the body of the car.
RESOURCES :
The Complete Idiot's Guide to Trouble-Free Car Care
Author: Dan Ramsey
ISBN: 0028635833
Alpha Books
Auto Repair for Dummies
Author: Deanna Sclar
ISBN: 0764550896
Classic Car Restorer's Handbook: Restoration Tips and Techniques for Owners ...
Model: 1557881944
Author: Jim Richardson
Order this book from Amazon.com
H.P. Books
Classic Car Restoration Guide: The Complete Illustrated Step-By-Step Manual
Model: 1850108900
Author: Lindsay Porter
Order this book from Amazon.com
Haynes Publishing
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