Need some advice TIG welding patch panels

[crawdaddy]

One thing I might add when welding thin panels some of your distortion is going to be caused by your weld bead shrinking as it cools.You should hammer and dolly your beads as you connect the dots between your tack welds.This will help stretch the welds and minimize warpage,and remember anytime you cool the weld quickly with compressed air or water it will shrink the metal, let your welds cool slowly.Mike

[pdog]

Got it, good point. I didn't fully weld the patch panel in the first quarter, so I can hammer/dolly from this point on while finishing it.

[wrenchnride247]

When you try the cut-off wheel method, keep it 90 deg. to the bead (like you're going to cut with it) and use light pressure so you don't dig into the base metal. Then switch to the "flapper" or sanding disc for a smoother finish.

[pdog]

Got it, thanks

[QuazI]

could try using a heat sink if at all possible....worked wonders for any thin stuff I've ever done!!!!

[KarateBoy]

could try using a heat sink if at all possible....worked wonders for any thin stuff I've ever done!!!!

That's one of the coolest thing I've ever heard.

any pics of the type of heat sink?

[nocheepgas]

That's one of the coolest thing I've ever heard.

any pics of the type of heat sink?

I use a big hunk of aluminum (2x4x6) and keep it in the freezer.

[wrenchnride247]

That's one of the coolest thing I've ever heard.

any pics of the type of heat sink?

Get about a 8-12" piece of 1" copper pipe from the hardware store, and flatten out about half of it. Then put about a 45 deg. angle on it. You can get fancy with a handle, or just wrap some electrical tape on it. You can make others with different sizes if needed.

[Blondie_486]

Dull abrasives will create lots of heat while grinding. You can't use a grinding disk until it's worn completely down while doing body work. You have to keep putting fresh disks on or else you'll end up heating the panel up and warping it.

Backstitch or backstep welding will also help to keep panel distortion down. Just imagine if you had to weld a new quarter panel on an Econoline van with an oxy acetelyne torch!! It's been done before.

Hope this helps a bit.

[Dmaxer]

If the hardness of your MIG welds is a factor making grinding them down tedious, try .023 ESAB Easy Grind (available in 11 lb rolls and larger). It makes for softer and more malleable beads.

If you keep your hammer/dolly work confined to just the weld, you can get the surrounding metal to return to it's original shape. When shrinkage occurs, it's just the weld puddle itself getting smaller, not the parent material.