Welding encouragement

[mmidland]

I have been looking at my Maestro and it has developed some rusty holes in the front bulkhead. Please refer to photobucket site
http://s260.photobucket.com/albums/ii9/Mreasto/
Can anyone give me any advice on how repairable this is?

I am keen to try my hand at welding and have acquired a 130A MIG welder but really need a little encouragement to have a go!!!

Would I need a new front bulkhead - are they available from Rimmers or can this be patch repaired?

A few minor questions - Where is the best place to attach the earth return on the car - as near to weld as possible?
Should I tack weld the repair plate first and then seam weld around it?
How do I protect the inside face of the repair plate?
I presume I need to cut away the light support panel for access to the front bulkhead and then weld a new panel on.

Cheers
Richard

[fatboy.01]

before doing any welding on the car and get some scrap metal to practice on first its easier to weld thick metal than thin metal and eaven harder to weld rusty metal but practice makes perfect

i personal would patch the hole sheet metal is fairly cheap think we (at work) pay less than £15 for 3x4 foot sheet all nice and clean and straight

just ensure that you clean up the metal up so its paint and rust free always handy to have a fire watcher if your welding were something could catch fire the best results are all in the prep work so dont rush

if it looks crap just grind it back

welding mask and glove's are a must have cos i can tell you first hand ark eye hurts alot

good luck

[E_T_V]

I have been looking at my Maestro and it has developed some rusty holes in the front bulkhead.

Can anyone give me any advice on how repairable this is?

I am keen to try my hand at welding and have acquired a 130A MIG welder but really need a little encouragement to have a go!!!

Would I need a new front bulkhead - are they available from Rimmers or can this be patch repaired?

A few minor questions - Where is the best place to attach the earth return on the car - as near to weld as possible?
Should I tack weld the repair plate first and then seam weld around it?
How do I protect the inside face of the repair plate?
I presume I need to cut away the light support panel for access to the front bulkhead and then weld a new panel on.

Cheers
Richard

Wow I've never seen a maestro go rusty there before. Very odd indeed. I'd guess at crash damage.

It is repairable but you'll have to fabricate a few bits and pieces to replace the rusted out metal work. When you start preparing it for welding expect those holes to grow to about twice that size!.

You can occasionally find a cross member with the headlamp panel attached which is a "crash damage" part so was readily available for repair work. Otherwise you'll have to cut out and replace a lot of that metal.

Best place to attach the earth return is any bare metal point on the car not too close to the welding that is going on but not miles away either.

Yes tack weld every inch or two then join them up with seam welds later.

Rear of panel is difficult to protect but paint if possible or waxoyl if not.

Its difficult to see exactly where on the car it is, but for the panels that are joined at right angles with a hole underneath, you'll need to cut away, re-instate the box section and then weld another patch to join it to the headlamp panel (i think it is this one).

[mmidland]

Thanks for the comments.
The main hole is in the N/S top of the front crossmember and appears to start where the vertical light panel is attached. I can find no evidence of crash damage and I think it has started with poor sealant around the light panel attachment leading to rust etc etc. The front panels (below light) had all sorts of rubbish behind them that just soaked up moisture encouraging rust. The 'drain channel' was full of muck that also prevented proper draining.
The cross member appears to be 1.6mm thick which is double the normal bodyshell metal thickness.
I have added a few more photos which show views from the inside of the engine bay.
Does anyone know the if light panels or front crossmembers are available from Rimmers?
Would I need to do any more than covering engine with welding blanket to prevent sparks?
I have also come across some weld thru' primer - is that any use?
Should I also weld up any unused holes in the top of the cross member to reduce water ingress or should I just use rubber plugs?

Cheers
Richard

[C191JOE]

I can't find the thread that appeared during the last few days about someone having to do some welding, but not having the skills.

I came across this: http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=160201786766,

whilst I was looking for something else. Its a CD course on welding and may be useful to other club members as well.

If you know who started the thread can you direct him to this ebay address, thanks.

[C191JOE]

sorry!
it is item no 150209860156

[E_T_V]

I've got a welding course notes somewhere on my PC which I'll see if I can dig out.

To be fair practice is the biggest thing though!

[MAESTRO_MONTEGO]

I've got a welding course notes somewhere on my PC which I'll see if I can dig out.

To be fair practice is the biggest thing though!

yep practice and more practice thats how i started,when i thick i could do it on a car i did it first great job and i was very cuffed and saved more a hell alot of money;)