COE Panel Welding - Bodywork

See those sweet cab corner patch panels? See that less then stellar patch to the former gas filler hole?

I'm about to install the cab corners but still have issues with warpage as evidenced by the filler hole patch.

I try to tack, tack, tack maybe an inch apart, then let it cool and I think that works OK, I'm more skeptical of my grinding which I try to do only until it's warm to my hand then stop and let it cool. But I still seem to get warping...

Pointers, tips, words of wisdom before I warp panels that cannot be replaced?

 

For what it's worth, I haven't figured it out either! On a situation like that gas filler hole, I tack once, cool with air hose, tack again right next to the first one, cool with air, repeat, repeat, repeat. (I don't skip around) If distortion becomes visible, I grind the welds down just proud of the surrounding metal, then hammer and dolly the welds to counteract the shrinkage. It is possible to hammer too much and end up with a bulge, this I shrink back down with my stud welder with shrinking tip. I'm sure others have better ways

 

Real good fitup helps a lot . You are going to get warpage ( shrinkage ) with all welding . Tig and gas welding are soft welds and can be metal worked ( hammer weld) as you go . Mig is a hard weld . When I’m replacing a panel with mig I use some easy grind wire , hard to find in most places . Big spaceing between tacks. I grind with a thin cutoff wheel in the same direction as weld this keeps the metal around the weld nice . Can’t really stretch a mig weld but you can hammer on dolly around it and get out most of the warpage .
If you are tig or gas welding leave a opening thr thickness of the metal and weld in that crack . Weld only about and stretch as you go , much easier .
Took a class with Gene Winfield and he showed me a way of laying the two panels over each other and cleco on a line where you are going to mate the two . You take a little air saw and cut from one cleco to the other and take your waste off each piece and you’ve got a perfect gap that may not be straight but is parallel to each other . You hammer weld that area then cut to the next cleco and so on . Saw and helped him do a whole roof and when it was done no grinding and it was straight. He is the man .
Skier, tried one of those grill bottoms and I’m going to have to study it more . Didn’t turn out too good . Will try going at it in a different way . May need a Pullmax . Good reason for a new tool just don’t tell the wife .
Hope this helps on patches . Used the hammer technique when I replaced the door skins on my cab over . Just a skim coat on the weld on one side . The other I metal worked . Guess which one .
Long winded , never type this much , Blue .

 

I skip around large areas so they cool and be patient. Very small tacks. TIG.... OK where do you find patch panels for a ford COE now days? thx

 

You have to make most of them , ther are a few parts but not much .

 

Check this out it helped me.

 

Thanks guys, this really helps! I like your idea about grinding with a cutoff wheel, Blue. As you mentioned, I can direct the "grinding" more on the weld over a flap disc.

 

I can't wait to try the overlap and cleco method. If you distort it up bad enough, you won't be able to get the clecos out.

 

Steve , I know your pulling my leg but I take the cleco out about 3/4” away . Also as I’m welding I try to hammer on dolly as quick as I can after welding . If gas welding I smack it while still red . Makes it flat .

Fuzzy , that’s a great video . Me and that didn’t mention to have both sides as clean as possible. Blue

 

You know I’m trying to get better at my panel building . If we were as talented as Josh Bullock at True Metal we would not need to use some of this old junk . Took a class and became a friend from Josh . Really nice guy . Some of his work .

Hung out with him and Jamey Jordan , great beadroller , at SEMA. Both have taught me so much . Wish I had known guys like this when I was younger . These two guys will be the future of custom work doing it the old way . Blue

 

It just boggles my mind that someone made those panels. wow..

 

I’ve always been a migger, one of these days I wanna be a tigger...

 

Miller has a special going on now ,$700 rebate . I picked up a new one after SEMA . With rebate and what I sold my Eastwood for cost me $410 .

 

Blue, I tried your cutoff wheel idea on some panel welds.... It really works like a charm!!! Very little heat compared to the flap disc.... thanks!!!