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welding Flat Work with bound/bordered/confined edges
Think of:
bread pan bottoms firewalls floors dash panels hoods Okay, on the topic of welding up holes, cracks, patches in these flat pieces.... One can get warpage and oil cans in payment (retribution) for one's gentle fitting, tacking and welding efforts. (I still remember my first firewall welding job, on a '29 Chrysler Coupe, steel, all holes and crax welded up. File-finished after two long weeks of sweaty arm-and-hammer heatn'beat workouts.) Aluminum panel from an early Luscombe (1930's airplane) needs HELP: P1010511.jpg 8 holes filled, 3 cracks welded, large patch installed. P1010520.jpg tig tacks, tig welds w/ both skips and long runs. P1010532.jpg skip weld, chase cracks, weld both sides, dress off welds - both sides P1010535.jpg 1st hammer-out, light sand w/180 to reveal So, 8 holes filled, 3 cracks welded, one lg patch in - on this small end panel. Left to do: Large hole to fill and small hole to fill - then on to other end panel to do the same all over again. Miller Synchro 250, 1981 5356 filler Rockmount filler I will go over the whole inst. panel at the end to level up and finish file. (Never know when hail happens during a job...)
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Kent http://www.tinmantech.com "All it takes is a little practical experience to blow the he!! out of a perfectly good theory." --- Lloyd Rosenquist, charter member AWS, 1919. Last edited by crystallographic; 10-30-2018 at 08:11 PM. |
#2
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Hi,
Nice save of the original Luscolme instrument panel. Did they have radios in the opening or a clove box? So many get cut up or changed out to a modern 1/8" thick flat panel. B
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Bill Tromblay "A sign of a good machinist, is one who can fix his F$@& Ups" My mentor and friend, Gil Zietz Micro Metric Machine. |
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Luscombe
Good save Kent, now if you can just find the original Budd die to make the firewall, it would make this year a beauty for me!
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Kym |
#4
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Quote:
Thanks. No luck on firewall dies. This bird is a very early model and is getting the full resto treatment. P1010536.jpg P1010539.jpg P1010543.jpg Now, on to the other end...
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Kent http://www.tinmantech.com "All it takes is a little practical experience to blow the he!! out of a perfectly good theory." --- Lloyd Rosenquist, charter member AWS, 1919. Last edited by crystallographic; 11-01-2018 at 01:31 PM. |
#5
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#2
As promised the other end got patched, same way -
P1010562.jpg ready for weld dressing, hammering, filing. Panel is set up for standing hand work, "handworking at the bench." P1010564.jpg Bright lights enhance visibility one thousand percent. As Bob Davids would tell me, "Do this or fail!" (bright illumination, reflecting off of surface = critical lighting. He is an old Art Center graduate, so ...) Note: stuff shown on bench, under panel = quick check spray machinist spray blue, Super Shear file rigid hard sanding block marlinspike spring steel spoon asst'd weight/face contour hammers P1010566.jpg "Spooning" with the forged spring steel spoon, to fine-level the surface with the marlin spike held under as "dolly." (both tools mfg'd by TM Tech) P1010569.jpg "Check file" the surface, using modified Super Shear file (source:TM Tech) P1010560.jpg filed surface - might want to compare this with my first/intro post. I am removing .002" material (demo measured during my "metal finishing classes) to simply "check" the surface, hence "check filing," a term used by pre-1960's metal guys who knew how to file, what files were available, and how to care for files. Files are one of the two fundamental hand tools. Good idea to know how to use one. - and so on to completion ...
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Kent http://www.tinmantech.com "All it takes is a little practical experience to blow the he!! out of a perfectly good theory." --- Lloyd Rosenquist, charter member AWS, 1919. Last edited by crystallographic; 11-03-2018 at 02:38 PM. |
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Kent. Because of such work, a payment was do made to the account. Because he could not recalculate metal money when was paying him, when his hand still knocked after work .....
Amazing work. Admiration. I will now test the aluminum bonnet on Mercedes without welding. I'm already scared.
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Jaroslav |
#7
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Hiw did you avoid oil canning? Love the airplane restoration projects.
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Scott in Montreal |
#8
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avoiding oil cans
Scott, I keep count of the number of hits I make per a given area, knowing that I am smacking the weld area to remove distortion, increase the hardness/strength, reduce the weld bead volume, and reverse the weld-shrinkage. Accuracy is vital for this, both in targeting the hits and in keeping numberical count. So many times I've arrived at the final leveling and filing pass to find a "loose" panel that quickly turns into an oil can. ... ... ... (sigh, and here we go again, I am saying to myself ...) So I keep the panel tight, all the way, with frugal hammer blows. And the last leveling pass leaves it nice and flat and tight.
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Kent http://www.tinmantech.com "All it takes is a little practical experience to blow the he!! out of a perfectly good theory." --- Lloyd Rosenquist, charter member AWS, 1919. |
#9
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the next step
Continuing onwards with my last pass of light corrective planishing and check filing -
P1010621.jpg The worked area slowly spreads out across the panel.... P1010626.jpg A very light sanding shows the surface more clearly ... I have one or two weld bead sinks that could use a bit of fill, upper area. Gas welding avoids these sinks, completely. Having to weld both sides using the tiggy makes the sinks a predictable risk when trying to use minimal filler. The dull contrasted surface in the 2nd photo now shows the unworked weld area very clearly. Remember that all of the welds were first dressed off and then hammered, so this remaining "lumpy-ness" is what the last pass is removing/smoothing. I left this area "down front" to be worked last so the contrast between "before and after" would be super clear and really evident! (Note: this is a "paint-grade" finish, and is not for going to a polished finish.) (In contrast - this is a typical gas weld, welded from one side and has been lightly planished with zero weld dressing (sanding/filing), below: C195 Wheelpant back side, welds showing.jpg top side, polished finish, below: C195 wp done 3-4.jpg
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Kent http://www.tinmantech.com "All it takes is a little practical experience to blow the he!! out of a perfectly good theory." --- Lloyd Rosenquist, charter member AWS, 1919. Last edited by crystallographic; 11-07-2018 at 03:05 PM. |
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Beautiful work as ever Kent. Can you tell me why you used TIG instead of gas, was it to keep the HAZ as small as possible?
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David Hamer |
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