Hey guys I am interested in learning how to do body work for my Mav. I have some rusted through areas on it that will require new sheet metal and I don't know how to weld very well - yet. I took some welding classes in high school but that was several years ago. Areas include small rectangle on passenger floor pan, torque box in same area, both rear quarters, one of my front fenders has a fist sized rust through also. Instead of purchasing new ones I would rather tackle the job myself and develop this useful skill. I figure if I screw something up, then I can give in and buy someone elses fenders or have someone else repair my rear quarters and floorpan/torque box. Heres what I need to know: What kind of welder do I need to buy? Where can I find said welder? What guage sheet metal do I need to use to repair these parts of my car? How do I go about shaping the metal before the weld in? What kind of grinders, cutters, or torches do I need? I realize I probably shouldn't use my car as an experiment for my first time welding so I am totally down for any recomendations as to how I should start out. I can weld random sheets of metal together until I get the hang of it if you guys think thats the best way. Look forward to all of your input.
Virtually all of these questions can be answered by using the search feature on this board. Then....using Google can yield a bunch of information. It might be for another car, but would still be appropriate. I know nothing about weleding, so that is where I would start.
I run a lincoln 3200hd welder (mig). have a 75/25 mixed bottle of CO2/argon. I would buy some 18 guage scrap steel to practace on, its pretty easy to punch holes in sheet metal. you can pick up this welder and gear at lowes for about 300-400, wire brushes grinders, pretty much everything you'll need. I would invest in autoshade helmet, well worth the money. I think you can also get metal shapeing hammers in stuff there, or any other hardware store. Plasma cutter is the best way to go for quick cuts but pricey and you dont want to over heat the metal and warp it. You can do most of the cutting with a metal cut-off wheel. I was a metal worker in the USMC, not civilian certified but I like to think I know what im doing. hah
Ok...Here goes. Go buy a book or two on " how to do bodywork/sheetmetal repair" Go to harbor freight and buy a cheap mig welder (mig is an abbreviation for Metal Inert Gas welding) Learn how to use it... Hand tools you "NEED" to do effective sheetmetal repair are as followes. A Blair spot weld cutter (get one in 5/16" and 3/8") for your electric drill. A good assortment of drill bits. Good pair of hand held sheetmetal shears. (Scissors for cutting sheetmetal) (a good pair of thick leather gloves as well) sheet metal is sharp and will cut you fast and infect the wound immediately. A good assortment of welders vise grips/clamps. A good bench vise with a 6 to 10 inch jaw and a minimum (8" deep throat < This is how far it opens) A set of body hammers/dollies. A good hand held electric grinder in 4" and 7" varieties. A fair amount of sanding blocks/devices and sand papers. Now would be a good time...If you can afford it to get a descent air compressor that will put out at least 10CFM @ 90PSI and have a minimum 60Gallon capacity tank. You can do with out it but, air tools do make the job of cutting/removing old sheet metal and finishing repairs faster and in some instances easier. A good electric sabre saw and good blades for cutting out old sheet metal (an air powered die grinder and or air saw and cut off wheels/blades workes better) if you have a compressor. A place with a stable environment for doing the work. (by stable I mean no rain/snow intrusion) Cold/hot can be dealt with... A good assortment of hand tools for disassembly...Gotta tear the car down to a point to affect repairs. A good floor jack and at least 4 GOOD jackstands. Theres a plethora of tools used for doing sheetmetal repair but what I have outlined are the basics needed for affecting good repairs. The more tools/better the tools and experience the prettier and more seamless the repairs become. Mostly,practice makes perfect. Most importantly... You need the desire/motivation to learn/do the things needed to accomplish the project and second most important... A clear plan that you can stick to finacially and physically. Gotta be honest with yourself about what you can and cant do, and what the project needs. There is lots more to this than a harbor freight shopping spree and a car to play with. But we all started somewhere and learned as we went along. You will too as you get into your project and ask questions, hit snags and find surprises you werent expecting. Its all part of the learning process that you gain experience/knowledge from which makes you good at it. Start with simple things you know you can accomplish, and go from there. Good luck man and allways have fun doing it.
