10 replies to this topic

[Hen1275]

I've been cutting out two rust patches on the bulkhead from where the bonnet hinges were hitting the metal and wearing away, and was wondering how I would go about welding in the new metal. Would I be able to cut a piece of sheet metal, bend to shape and plug weld it over the two repair holes, but make sure I've painted the sides of the pieces of metal that are together and then use sealant around the outside? Or is this a bodge repair?

I've attached some photos of the cut out patches.

And obviously the surface rust on the metal around the hole in the picture will be cleaned up first.

 

 

 IMG_1260.JPG   76.36K   59 downloads

 IMG_1259.JPG   42.31K   43 downloads

 

Sorry about the image rotation. They seem to have rotated 90 degrees when I uploaded them.

Any advice would be greatly appreciated

Thanks

Edited by Hen1275, 06 February 2017 - 06:48 PM.

[sonikk4]

I've been cutting out two rust patches on the bulkhead from where the bonnet hinges were hitting the metal and wearing away, and was wondering how I would go about welding in the new metal. Would I be able to cut a piece of sheet metal, bend to shape and plug weld it over the two repair holes, but make sure I've painted the sides of the pieces of metal that are together and then use sealant around the outside? Or is this a bodge repair?
I've attached some photos of the cut out patches.
And obviously the surface rust on the metal around the hole in the picture will be cleaned up first.
 
 
IMG_1260.JPG
IMG_1259.JPG
 
Sorry about the image rotation. They seem to have rotated 90 degrees when I uploaded them.
Any advice would be greatly appreciated
Thanks

I replaced the metal under my bonnet hinge mounts on Project Paddy in my signature. All you will need to do is make it bigger with some minor shaping.
All very doable.

[Hen1275]

Thanks for the reply. I've just had a look at project paddy and the repair that you did on the panel and saw that you butt welded the new piece in. Would I be able to spot weld a piece in or is butt welding the best way for this sort of repair?  

 

Cheers

[sonikk4]

Thanks for the reply. I've just had a look at project paddy and the repair that you did on the panel and saw that you butt welded the new piece in. Would I be able to spot weld a piece in or is butt welding the best way for this sort of repair?  

 

Cheers

 

It needs to be seam welded unless you are replacing up to the top of the dash rail. That area can be spot welded but the rest must be seam welded.

[16vmini]

yep , just cut a nice straight 4 sided hole, and but weld a new piece of metal in. 

[Hen1275]

Okay thanks for the replies, much appreciated. I'll cut the holes into squares and butt weld the new metal in.

[16vmini]

i only said square as i find more sides the hole you cut is trickier it is to make a plate to match , but not impossible either  , straight edges do help 

[tiger99]

In a few cases a circular repair is also effective because it can readily be marked out with a pair of compasses, or draw round a suitable disc. Best on flat surfaces.

Awkward shapes of hole, which are sometimes unavoidable, need a template for cutting the patch. Hold a piece of cornflake packet against the back and draw round the inside edge of the hole. Cut accurately to the outside of the line. Put the cut piece down on your sheet metal, using double sided tape if necessary, scribe around the edge and cut to the scribe line. You should get near enough without needing lots of filing.

[Stu.]

I enjoyed repairing the bulkhead on my 25. Quite a challenge but it worked out well. The inner wings have been replaced simce this photo too.

 

 

 

 

 

[lawrence]

A tip someone gave me for patch making is similar to tigers. Put a nice bit of thin clean cardboard over the hole and use your grubby fingers and go round the outside. This will give you the outline of the patch you need and save you buying a pen! 

[tiger99]

I could have suggested that but then I would be admitting to having grubby fingers!

 

I tend to wear blue disposable nitrile gloves these days, to avoid seriously nasty hazards like old oil, so my fingers are usually clean.