Great thread Hendrik.
Interesting to see how you approached strengthening the roof frame. I'm guessing the 1.2mm cover plate replaced thinner original metal? The metal on my '84 RRC body all seems to be about 0.9mm or less (or totally absent
).
Did you use a dedicated spot welder when installing the 1.2mm plate, or your MIG?
If with MIG I would be interested in your method, particularly out of position. In my rust removing efforts I would drill out the original spots in the top layer using a home ground point 4mm diameter, leaving the second layer underneath basically unscathed. Fabricate the new piece with 4mm holes.
I had trouble welding in new spots when I left the holes at 4mm. The MIG arc would short to the side of the hole instead of the centre of the second layer. This gave the weld a lopsided appearance as it burnt into the top layer, leaving a large part of the original hole still evident.
I ended up making holes 8mm diameter to better control arc direction.
I watched lots of youtube vids but none seemed to go into power settings.
After lots of frustration I thought stuff it and set my 22 year old MIG to full power (6th setting). Held the gas shield sheath right on the hole and let rip for about 2 seconds, expecting to burn a big hole. But no, the hole was fully filled with just the right penetration through the second layer. Destruction test of the practice piece had the first layer ripping around the weld. I thought you beaut, cracked the MIG spot weld secret. But out of position...good old gravity had other ideas.
Also liked you adaption of the transfercase to gearbox.
Bookmarks