Tools and tips for metalwork
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Senior User
Joined: Mar 2003
Posts: 125
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From: Sanford ME
Tools and tips for metalwork
OK, so last year I took care of some rust over the rear wheel arches on my 93 F-150, and this year, after it rusted up again, I ended up cutting a moderate "chunk" of metal out over the passenger side rear wheel arch. (Maybe 12 inches long by 4 to 5 inches high)
I hope to get some sheet metal and make a patch to weld in but I was hoping for some tips....I don't expect this to come out perfect but if I can make it decent looking, prime it, paint it and not worry about the rust for a while I would be happy.
So, what I am really looking to find out is this: What should I be looking for in the line of sheet metal and what types of tools will work best to cut/shape it with? Also, what about welding tips? My dad knows how and will most likely assist but I have never used a welder before...how hard will it be to make a couple of "tacks" to hold the piece on?
This is my first attempt at any of this so if there are any pitfalls I should be aware of, well, I would appreciate any info anyone has.
Sorry for the long post and thank for the help!
I hope to get some sheet metal and make a patch to weld in but I was hoping for some tips....I don't expect this to come out perfect but if I can make it decent looking, prime it, paint it and not worry about the rust for a while I would be happy.
So, what I am really looking to find out is this: What should I be looking for in the line of sheet metal and what types of tools will work best to cut/shape it with? Also, what about welding tips? My dad knows how and will most likely assist but I have never used a welder before...how hard will it be to make a couple of "tacks" to hold the piece on?
This is my first attempt at any of this so if there are any pitfalls I should be aware of, well, I would appreciate any info anyone has.
Sorry for the long post and thank for the help!
Admom
Joined: Feb 2001
Posts: 9,414
Likes: 201
From: Silver Springs
You might start by reading the Patch Panel/Rust Repair thread at the top of this forum. Here's the link.
https://www.ford-trucks.com/forums/s...ad.php?t=82480
https://www.ford-trucks.com/forums/s...ad.php?t=82480
Postmaster
Joined: Nov 2000
Posts: 2,557
Likes: 2
From: Texas
Use a jig saw or sawzall. The edges can be cleaned up with a grinding wheel easily.
Start by cutting out the rust, all of it, leave nothing. Using the opening as a guide, slide a piece in behind the opening and mark it with a scribe. Use your jigsaw to trim just off the line, anout 1/16" as you can use the grinder to "trim" the panel.
Once the piece fits nicely, use a couple of magnets to hold in in place while you tack it into place.
Once the panel is tacked in several places, you can use spot welds (small welds about 1/8" long) to fully weld the panel. Do not get in a hurry here as you can damage the panel easily by overheating. Space your spot welds at least three inces apart and alternate around the edges rather than one right behind the other. If you do three or four, stop and let it cool to touch before doing anymore.
Start by cutting out the rust, all of it, leave nothing. Using the opening as a guide, slide a piece in behind the opening and mark it with a scribe. Use your jigsaw to trim just off the line, anout 1/16" as you can use the grinder to "trim" the panel.
Once the piece fits nicely, use a couple of magnets to hold in in place while you tack it into place.
Once the panel is tacked in several places, you can use spot welds (small welds about 1/8" long) to fully weld the panel. Do not get in a hurry here as you can damage the panel easily by overheating. Space your spot welds at least three inces apart and alternate around the edges rather than one right behind the other. If you do three or four, stop and let it cool to touch before doing anymore.
Thread Starter
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Senior User
Joined: Mar 2003
Posts: 125
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From: Sanford ME
Thanks Rosati, this sounds so basic in concept I never would have guessed...
Another quick question, where is the best place to seek out the sheet metal that I need for this project? I'm on a light budget so cheaper is better, i.e. if I can purchase just what I need and not much more that is probably best.
Anyway, thank you all for you pointers, I hope to tackle this next weekend.
Another quick question, where is the best place to seek out the sheet metal that I need for this project? I'm on a light budget so cheaper is better, i.e. if I can purchase just what I need and not much more that is probably best.
Anyway, thank you all for you pointers, I hope to tackle this next weekend.
