I have a theory, tell me would this work?

  • Thread starter hudson hornet !
  • Start date
H

hudson hornet !

So, I have been thinking about the flanges we weld when joining rockers, quarters, etc.

There are many ways to protect the seam after plug welding, but what about this?

1. Make sure both flanges are clean per Barry's tech sheet

2. Plug weld panels with NO weld through primer- both flanges would be bare steel

3. Over reduce epoxy and pour epoxy into the flanges along the full length allow to drip out.

What do you guys think? OK or no? I never want my Charger to rust again lol.
 
simple solution here.....dont lap weld anything. the flange should be cut off and everything butt welded then grinded smooth like there isnt even a seam.
 
simple solution here.....dont lap weld anything. the flange should be cut off and everything butt welded then grinded smooth like there isnt even a seam.

Exactly my thoughts.

You can use easy grind wire on a mig to make the weld easier to clean up too.
 
Guys he's talking about replacing panels, like replacing a outer rocker panel, or perhaps a quarter panel. I think he's asking about those type of flange's not lap welds on a patch. (which you should never do) I used to do the weld thru primer thing but realized that was pointless and didn't provide much protection. Now I epoxy the back sides(inside) of the flanges then when they are set in place and after the plug weld holes are done, I simply scrape away to bare metal inside the plug weld holes. After you are finished welding and grinding, reapply epoxy on the front and backside of the flange. If it makes you feel better you could also try using a roller or brush and work some into the topside of flange where the two join. Main thing make sure you have good coverage front and back.
 
I either glue them when I can or use weldthrough + pour(spray) epoxy after the fact. If I can get at the seam I'll turn the spray gun into a pencil tip and flood the seam and release the trigger slightly for just air and force it into areas. This does a good job.

I always pour a medium PPS cup or epoxy into each door and rotate around into all the seams and then let it drip out. Makes a heck of a mess but works good.
 
I should have been more clear fellas, these are all new panels in a restoration. I was specifically talking about factory flanges that would have been spot welded, but now would be plug welded. My idea is to plug weld the panels together and then pour over reduced epoxy in the seam.
 
Whatever,We do,IS an 'improvement' over about 'any' Factory gig because We ain't making a 'hundred a day' and only a small 'deadline.
They envy Us because We have the Time and Product,which They didn't but still turned out in Amazing fashion considering,Huh?
We are replacing the Past for Preservation Of Them and do what Is 'necessary' to Preserve Them as We have the Time too gentleman.
I use epoxy in any form or fashion when necessary to Protect Them because They will not Ever pass this 'way again.
 
Anything you do will be better, but if you think about it the factory seams held up very well considering what they were exposed to. The rust on most of the cars from the southwestern states is where the water was trapped because of plugged up drain holes, and of course cars from the desert are going to last a long time without rust, but it does rain in the desert occasionally. So how much inclement weather is your car going to be exposed to?

I have a 57 Chevy hardtop that spent the first 30 years of its life in Los Angeles Ca--outside, and for the last 29 years it has been in Michigan parked in an unheated barn. I have looked inside the quarters and doors and there is very near zero rust except on the bottom of one door at the weather strip holes, it looks like someone may have glued the weather strip which trapped the water.

28f5f14d-2fc1-445d-b852-e75cfdb775b3_zpshnlmo2bi.jpg
100_4086.jpg
 
obviously every car is different, but most of my older cars, 1970's Firebirds, were dragged through swimming pools full of e-coat and primer, then baked at the factory. It didn't solve everything, and you know that if you drove a Camaro in the salt, but they really did make a decent effort to get paint on them inside the rocker panels.
 
I typically follow method similar to what Chris mentioned above when assembling adjacent panels. I'll just use epoxy between the two, as shown here painted on the rear tailgate opening, and also on the underside of the tailpan. This provides rust protection where in many cases the factory process does not add any paint until after assembly. In cars like this 55, in many cases the inner voids such as in the rockers or floor crossmembers never receive any paint finish inside, making them prone to moisture and rust issues.

Where this epoxy will not allow welding, you will need to clean the paint off the adjacent panel within the drilled plug weld hole.


Picture314.jpg



Which is what brought about the need for this tool, made from the same size drill bit I used for plug weld holes. It gets flattened and back-faced to resemble an end mill cutter.


Picture315.jpg



Picture316.jpg



This shows how it works, cleans the paint from the metal surface, but having a flat face on the cutter, it doesn't try to drill through the metal as a regular drill bit would.


Picture318.jpg



welded......


Picture321.jpg




For application, I'll either spray inside my paint booth or for a small application like you see here, I'll mix up some epoxy and brush it on. (note brush strokes in first pic above) The application process won't matter much as any exposed epoxy will be sanded and re-applied later, but now that we have some epoxy between the two panels, there is better rust protection regardless of how it got there. Once welding is complete, mixing up additional epoxy and allowing it to run between the two adjacent panels only helps to seal the joint even more. For door skin installations, I'll epoxy both surfaces separately, assemble, and then pour epoxy inside the door and roll it around to seal out seam where the panels meet. Anything we can do to seal out the moisture will only serve to help these cars last even better on their second lease on life..
 
Last edited:
I've often wondered how to clean primer off inside the spot weld holes, that's a great idea! I had planned on trimming down a battery post terminal cleaner to a smaller size, but the drill bit is a much better idea!
 
We've been using a variation on that for many years, in our shop, double-ended 1/8" bits get worn a lot and they're not worth sharpening, so a quick grind on the end turns them into a smaller version of the tool shown above, with the difference that they are much smaller, but this can be an advantage sometimes if the surface below the hole is not totally level.
 
Back
Top