Welding question about body work....Anyone?
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Professional
Joined: Jul 2011
Posts: 138
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From: Livonia,MI
Welding question about body work....Anyone?
Okay so i have a little bit of welding experience from my auto class back in high school, of course it was a tig welder though. I have some rust that i want to fix on my truck. I have already priced the panels i need from LMC truck, and i know how to use bondo. I have an arc welder but those take some practice, Harbor freight sells a 90amp flux welder for under 100 bucks, my only question is......i hear people say they can weld with a flux core and people say they cant? i dont know who to believe, i dont have enough money to spend on a mig or tig with gas....any input would be greatly appreciated, thanks
Champion
Joined: Sep 2011
Posts: 3,891
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From: NorCal
People that say they can't weld with flux core just aren't doing it right. As with any technique, it takes practice, ergo time. You may suffer quality, meaning more grinding for cleanup or other, but hey...it's join up. If you go that route, then you'll be proud to shove 'em a finger or two.... 
It's your budget.
It's your budget.
Professional
Joined: Feb 2011
Posts: 152
Likes: 0
From: South Carolina
I was in the same boat and ended up with a Lincoln welder. I just did a lot of "YouTube" watching and took my time. I eventually leased a tank of gas for welding other stuff but the flux core will work on sheet metal. Just make sure to pay attention to the settings and do a bunch of short welds so you don't burn through the metal. Obviously I learned trial by error.
Record Breaker
Joined: Aug 2010
Posts: 2,241
Likes: 12
From: Ohio
Also, be sure to remove ALL the flux before you start do the filler work. If you dont, wherever there is flux, there is NOT adhesion. Also, of you plan on keeping the truck for any length of time, do NOT use Bondo brand filler. Its garbage. Use a filler like Evercoat. Its more expensive, but worth it in the long run. You can try to find it at various auto part stores or online like here: http://www.autobodytoolmart.com
Rookie
Joined: Jun 2011
Posts: 86
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From: New Hampshire
I used a lincoln flux core 110V Weld Pack welder ($100 on craigs list) to put new lower door panels on my truck. Never welded before. read up on it and watched alot of youutube vids first. Practiced on some scrap metal first. You'll want to use low heat on the body sheet metal and (depending on your skills) expect to blow some holes through the metal. I welded in a backer strip to attach to (forget butt welding), used lots of clamps and pre-treated the seams with a weld-through galvanizing primer.
Once you get the metal fitted, clamped and tight, do tack welds every 2-3 inches, starting in the middle and alternating each side, to minimise heat warpage. Then fill the gaps between the welds with shorts beads, again alternating to non adjacent segments.
Expect it to be messy, Keep a wire brush/wheel handy to clean up the flux residue as you go. Use a grinder and some flap wheels to smooth out the globs of metal.
Get it clean of flux residue and any oils before applying filler. I used bondo and duplicolor from autozone for finish and paint. I also coated the interior of the metal with galvanizing primer and PB Corrosion stop to prevent rust from the inside out.
Now I've got the only 2nd gen Ram in the neighbourhood that doesn't look like a rust monster gnawed on my doors!
If I can do it, I'm sure you can!
Once you get the metal fitted, clamped and tight, do tack welds every 2-3 inches, starting in the middle and alternating each side, to minimise heat warpage. Then fill the gaps between the welds with shorts beads, again alternating to non adjacent segments.
Expect it to be messy, Keep a wire brush/wheel handy to clean up the flux residue as you go. Use a grinder and some flap wheels to smooth out the globs of metal.
Get it clean of flux residue and any oils before applying filler. I used bondo and duplicolor from autozone for finish and paint. I also coated the interior of the metal with galvanizing primer and PB Corrosion stop to prevent rust from the inside out.
Now I've got the only 2nd gen Ram in the neighbourhood that doesn't look like a rust monster gnawed on my doors!
If I can do it, I'm sure you can!
Last edited by knoxy; Jan 17, 2012 at 12:41 PM.
Champion
Joined: Sep 2011
Posts: 3,891
Likes: 8
From: NorCal
I used a lincoln fix core 110V Weld Pack welder ($100 on craigs list) to put new lower door panels on my truck. Never welded before. read up on it and watched alot of youutube vids first. Practiced on some scrap metal first. You'll want to use low heat on the body sheet metal and (depending on your skills) expect to blow some holes through the metal. I welded in a backer strip to attach to (forget butt welding), used lots of clamps and pre-treated the seams with a weld-through galvanizing primer.
Once you get the metal fitted, clamped and tight, do tack welds every 2-3 inches, starting in the middle and alternating each side, to minimise heat warpage. Then fill the gaps between the welds with shorts beads, again alternating to non adjacent segments.
Expect it to be messy, Keep a wire brush/wheel handy to clean up the flux residue as you go. Use a grinder and some flap wheels to smooth out the globs of metal.
Get it clean of flux residue and any oils before applying filler. I used bondo and duplicolor from autozone for finish and paint. I also coated the interior of the metal with galvanizing primer and PB Corrosion stop to prevent rust from the inside out.
Now I've got the only 2nd gen Ram in the neighbourhood that doesn't look like a rust monster gnawed on my doors!
If I can do it, I'm sure you can!
Once you get the metal fitted, clamped and tight, do tack welds every 2-3 inches, starting in the middle and alternating each side, to minimise heat warpage. Then fill the gaps between the welds with shorts beads, again alternating to non adjacent segments.
Expect it to be messy, Keep a wire brush/wheel handy to clean up the flux residue as you go. Use a grinder and some flap wheels to smooth out the globs of metal.
Get it clean of flux residue and any oils before applying filler. I used bondo and duplicolor from autozone for finish and paint. I also coated the interior of the metal with galvanizing primer and PB Corrosion stop to prevent rust from the inside out.
Now I've got the only 2nd gen Ram in the neighbourhood that doesn't look like a rust monster gnawed on my doors!
If I can do it, I'm sure you can!
I think this is great advice!!
Administrator
Joined: Apr 2010
Posts: 87,399
Likes: 4,214
From: Clayton MI
When I did body work..... when replacing panels, I would just tack the panels together every few inches, and then fill the rest with lead...... (yes, it has been a LONG time ago....)