another cab corner/rocker post

[dumbucket1]

I have done a search and only finding vague answers. When putting on cab corners and rockers are you butt welding them to the old metal or are you leaving 1/2" or so of metal and over lapping. If over lapping can't you tell there is metal sticking up higher than the rest when finished? Also are you using 100% argon gas or a mixture of gases and what wire size do you recommend .023? Thanks

[123 pugsy]

I always prefer to butt weld everything. I feel if you overlap , you will have a good place for rust to start to form. As for wire size I wouldn't know. I TIG weld everything although I would think the smaller the better for less heat. Just my 2 cents.

[Blazin]

When using a Tig welder but weld is the way to go. Problem with a Mig is when set high enough to penetrate they burn through easy. But weld is the absolute correct way, but a 1/8" to 1/4" over lap works well. As far as metal sticking up thats where precise grinding and a bit of filler comes in. .023 non flux wire is what you should use on body panels.

[dumbucket1]

I only have a mig welder and limited experience with it so looks like I may overlap. I will weld on scrap first to get a good feel of it.

[123 pugsy]

A piece of copper or aluminum as a backer can help from blowing through if you have problems. As Blazin mentioned,keep the overlap small.

[Blazin]

Yes the coper or aluminum tricks works well, but you have to be able to get it in behind the parts.

[cougarkiller]

well being a welder by trade i might be able to help out a little. These guys have got you off to a good start. Definetly butt welld the joint. Use a right angle magnet if you have to they are cheap availiable wherever they sell welding supplies. This will help with the fit up. Use roughly a 1/8" gap between your base metals (your two parts) make sure that your fit up is good and double check everything before you think that more material needs to come off of your parts. Because if you end up with a big gap, i wish you good luck. Very hard for a beginer to get a decent weld with a big gap. BE SURE YOU TAKE YOUR TIME if you want quality. When you have it all fitted in with your magnets in place use the copper or aluminum behind your weld. This helps for a backing for your weld plus as a heat sink. If you cant get behind your welds easily use an old contact tip from the welders stinger (or whip) you should have some extras around. They are made of copper. Use some pliers to hold onto this it will get hot. As for wire size i would not go bigger than .030" and for the gas i would recomend a mixture gas of argon and c02. Set your heat settings on some scrap steel the same size with the same gap thickness. Not knowing the make of welder or size/power source i cant help a whole lot with the settings. Make sure you get full penetration as this is a gap weld if you dont, when you buff the welds flush they will crack. When welding use spot or tack welds and off set them i.e. tack your coners first then the middles then the middles of that and so on, this will prevent warpage and distortion. Next buff the welds flush with a grinder and please use a buffing pad not a grinding stone, this will gouge your fresh welds, and we all know the key to good paint is good steel. Use something like a 60 grit buffing pad and start off lightly. Try to buff with the same motion like up to down or side to side. well good luck.