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Body parts or frame? What type of welder are you planning on using? I would use a MIG or TIG so you have more control over the welding process as far as amperage, so you don't warp any body panels. As far as what to disconnect and what not to, I would disconnect your battery at the very least, and I'm guessing just to be safe, disconnect all of your control modules (ECC, ABS, etc.). I don't think it would be much of an issue, though since you're not going to be passing current directly through any circuits. Exhaust welding isn't much the same, since most of the time you have rubber vibration mounts that separate the exhaust system and the body / frame. Never hurts to be too safe, though. Just be careful not to damage any wiring connectors -- but at the same time, also look for damaged items and burned wiring / connectors. May save you future headaches to find things like that now and correct them in the process. You will also want to sniff your fuel lines and gas tank as well. If there are any vapors present, do NOT weld until you figure out where they are coming from! You will also want to take care when welding near the tank and filler. You can use wet rags to dissipate some of the heat on the body panels, etc. Depending on what you're doing, I would also consider using 1/8" diameter rivets and body filler, especially if you're planning to repaint, etc. Just my $0.02
YES! Disconnect both battery cables, remove the CPU and RABS modules. I might remove the TFI too.
I have MIG welded on my own vehicles where I have blown the brake light bulbs just welding a foot or two away from them with both battery cables disconnected and the clamp right on the frame not even a foot from where I was welding a new bumper on. Current travels and not always how you think. The bulbs worked fine for a day or two and then they all went out. Maybe they got nuked by the RF, don't know.
It sure wouldn't hurt to disconnect the battery but, I welded all over mine when I did my chop top and installed the ranger bed rails and I never disconnected anything. If I had it to do again I still wouldn't disconnect.
Hello,
I second the warning on the gas vapors, as well as welding in a garage that has a gas fired water heater in it. I have MIG/TIG/ARC welded on many vehicles and have never killed any computers or other electical items. I do disconnect the negative batt cable as a safety measure though.