Welding Gaps In Sheet Metal

Tack in a few places apart from each other and wait until the panel is cool to the touch.

Welding gaps in sheet metal.

There are 2 basic methods to mig welding large gaps the first is to use filler metal to help cover the gap that is cut to size to fill the gap and help make the weld a smoother process. During the welding process the metal will get hot and the gap a welder leaves will compensate for the expansion that occurs. Tack weld in place. Tack welding is the best way to hold the metal in place before you fully weld it to the original metal.

For sheet metal i use ine welding wire and it is just as good as their flux cored wire if you want you can grab one here. The second is to do a root pass to fill the bottom of the gap and using stringer beads to fill the gap. Fit up and joint design. Imagine a butt weld on 20 to 24 gauge metal.

To avoid rework follow the measure twice cut once rule. Avoid warping the sheet metal. I ve been trying to cut and fit the pieces nice and snug together very small gap less than the wire diameter and doing the individual tack stitch weld technique. While replacing body panels overheating and warping thin sheet metal is common.

Then tack between the two previous tacks. If the parts fail to touch each other for even 1 16 inch you have created a hole that invites burn through and a gap that can t absorb the heat. Short bursts or tacks will help. Try going for a wire of 023 inches when welding sheet metal.

Welding thin metal demands tight fit up. This video explores some techniques that can be used to achieve. It doesn t matter as much it it s a bit smaller because if there s a very small gap this can be filled with filler metal. Close them up with your flux core or stick welder using this method.

Place the welding tip wire at the gap and tack weld several small spots spacing them evenly apart. While wire feed welding sheet metal go for short bursts of welding instead of a going on a long bead. If you re fitting a lot of tubes don t be surprised if you run into a gap or two eventually. When mig welding a patch panel on your car body panels you should think of leaving small gaps between the patch panel and the original metal.

Make the replacement metal is not larger than the original metal or it will not fit.