Ep9 Welded Door Patch Panels

Ep9 Welded Door Patch Panels

So what I have here is my passenger side door,
which I’ve had to cut a large portion of the bottom out. Which, as you can see here
on the outer panel, it was very rusty. Along this out panel edge, I allowed the edge
to have a flange. That way once I bring my already fitted replacement piece for the outer
panel against this, and I’m ready to weld, I’m just gonna plug weld against the flange.
That way I’ll get a lot less blow-throughs and I’ll create a cleaner edge.
With this inner panel, I’ve already had to cut out a lot already, but I do need to
cut out more because I left this corner here for aligning the outer panel. But I’ll be
ready to cut this out here in a minute, as you’ll see.
This hinge, it was rusty, but not rusty enough where I couldn’t save it. So I went ahead
and sandblasted it and put some weld-through primer on it, that way I didn’t have to
worry about it rusting until I was ready to work on it.
So now I’m gonna go ahead and cut that off and show you how to plug weld.
Let me show you why I had to leave that corner in. This inner panel fits in this outer panel
along the bottom edge, and once I’m finished, I’m gonna have to spot weld along this line.
And so, if I don’t actually know where this inner panel piece goes, I’ll be a little
stuck once I try and put everything together. But since I had the old corner in, I could
fit this outer panel right in the right area, and that way, once I actually weld this in,
I can weld this in, knowing that it won’t have a problem.
The first step to plug welding is to create a flange, which I’ve already done as you
can see here. You create the flange using this air powered hydraulic air punch slash
flange tool. On this side right here is the flanging part, which you would just put up
against your edge and press the button, and it’ll flange your corner. Then on the other
side, which is the next step, is a hole punch, which I’m going to put every two inches
along here. On my welds, I want to clean off the area
where I am going to be welding, that way I get a cleaner weld. And even though this is
weld-through primer, I don’t trust it all that much, so I’m just gonna clean it off
anyway. First I’m gonna tack the corners here, and
then I’m gonna start welding my plugs, going around the circle, then going in to fill it
in. Here is a plug-weld, which is near completely
perfect. It’s a little bit longer than it needs to be because I had a slight slip of
the hand, but it’s near perfect. And once I’m done doing all my plug welds, I’m
gonna come back to this corner and do some butt-welding.
When welding sheet metal, you always want to weld to the middle of your sheet. So I’m
going to plug weld here, then here, then here, and then I’m going to go into the middle
of those sections. And if you’ll also notice, I have a clamp right next to the plug weld
I’m going to be doing first. That way the metal will be right up next to each other,
and I know that there’ll be no gap. For the corners, I’m going to need to butt-weld,
and so since I know that these won’t warp as easily, I can do a continuous weld in a
spiral type of motion all the way until my flange starts.
There’s a little bit of blow-through, so I’m gonna let that cool down and go to the
other edge. I blew through again. Since I had a little blow-through, I lowered my arc
voltage, that way I won’t get as much heat for the blow-through.
My butt-welds don’t look absolutely perfect all the way around, but they’ll do. However,
my plug-welds look really nice, and I’ll show you a trick to how you can tell that
they really do look nice by flipping over this door. If you look at the back side of
my plug-welds, you can see that the welds went all the way through both pieces of metal.
That’s how you know that you really have a good weld.
I made marks to where I cut my original inner panel out, but I’m not gonna cut along that
line. I’m gonna cut about an eighth of an inch out and test fit it, and then I’m gonna
keep grinding down that edge until I get the perfect fit.
This inner door patch has taken several hours to fit, and remember kids, it’s very important
to get the perfect fit. That way it makes the welding a lot easier.
I’m gonna tack the inner panel in place before I do my final welds.
You’ll notice that I blew through because my gap was a little bigger there, so I’m
gonna go ahead and grow a bubble, and then use that bubble to fill the blow-through.
Now I’m gonna do all the plug welds on the bottom and the sides, and just like before,
I’m gonna start in the middle, then split the difference.
And I
just welded to my pliers!
Whoa! Oh, Oh that’s not good! I’m gonna finish my butt-welds, and the
easiest way to do that is a series of tacks. As I did before with these, I’m gonna start
in the middle, then keep separating the difference. Just in case you didn’t know, I’m hopping
around because this also heats up the metal, and I don’t want to warp the metal.
Now I have all my welds ground down, and as you can see on the outside of this door, my
plug-welds finished very nicely. Now this door will be ready for some body filler, and
I can paint over that and this door will be as good as new.
See you next time on Hannah’s Bug! As always, this show is filmed in front of
a live studio audience.

100 thoughts on “Ep9 Welded Door Patch Panels

  1. I think your wire feed speed is a little high. The sound is a bit wrong and It seems that the wire is pushing away the panel and that's indicative of too high of a wire feed speed. Turn it down a little and see if that makes things easier.

  2. Really nice. Idk whos teaching you all this but ima guess its your dad. Very smart man. You have a lot to thank your old man. Very good to see & watch. 👌✨

  3. Hanna, estoy sorprendido, yo también soy soldador, haces un trabajo muy bueno y prolijo. Te felicito por tener ese entusiasmo al realizar un trabajo que no lo hace cualquiera. Solo te recomiendo que uses una protección sobre tu cabeza, pero pegada a la máscara de soldar, así evitas que alguna chispa pueda dañar tus bellos ojos. Saludos desde Chile. Atte Andrés.

  4. While I think it's great you work on your own car, I wouldn't recommend welding at a young age because it can cause eye problems long term. Flashburns, welders flash, or uv keratitis.

  5. The first video that i have seen from you and i was laughing so hard. The love for welding. Keep it up and you can do anything you want. Thumbs up…

  6. I just found your video and book marked it. I am raising two grand kids that are 15 and 16 now and I am home schooling them. We are always discussing the importance of knowing how to build and fix things, so you will now be part of our class.

  7. Hannah, you are amazing, very nice vid, parents must be very proud how you are growing up and what you have accomplish. you little lady keep going in the direction you are going never give up. never say I cant. again great job

  8. Okay I was kidding… but those gloves SUCK… get these:


  9. or https://www.ebay.com/itm/TILLMAN-52-ANTI-VIBRATION-MIG-WELDING-GLOVES-M-L-XL/371863605000?epid=1100314470&hash=item5694cc4f08:m:mCiXNmGht37zTO8dTiLgsww

  10. One suggestion. Turn off autostabilization when you upload videos. It makes your video look all swishy and distorted. I don’t know why YouTube hasn’t fixed that yet.

  11. wow she has even put me to shame with the welding. am very impressed! amazing! like and subscribe from me for start offs.

  12. If you can access behind the panel you can stick a chunck of heavy brass or copper behind where your welding as a heat sink helps for warpage and burn through

  13. amazig hoo shame on me i cant weld thin metal witout burning holes and old fart a lot to learn from a small girl with a welder in a hand but my welder only have a two power for weld and a dial for speed of wire feeding

  14. That's right give your kid a grinder and a welder. Perfect life lesson on how to fix things rather than to just throw it away and expect there parents to pay.
    My hats off to parenting skills. M

  15. Hannah, you are amazing, in fact your jobs are much better than the jobs of the "profesional mechanics" in Mexico, I am sure in 4 years more you will be able to work with Chip Foose. I am very very amazed with you, I am car collector I have more than 12 classic cars to restore, I used to pay for the work, but I realized I am able to do by my self, you are an inspiration, I will show your videos to the guys of my club. Thanks for the video!!!!! And I hope soon you upload more.

  16. Wow….. you're an awesome hard working lil lady!
    You got my subscription!!!!

    Would give 2 thumbs up as well if I could!

  17. I’m 13 and i am restoring a big red 300 and the only thing I can’t do well is weld I can strip anything down and rebuild it I will end up getting my own one to practise more

  18. I have the same welder and could u possibly tell me what is your mig 135 settings set at for this weld? I can't seem to find the right settings. Btw great weld job kid! 👍

  19. Great stuff Hannah! I just bought the same welder. What are your settings for this patch? I'm trying to dial in my machine. check out the work I have ahead of me. https://www.youtube.com/watch?v=c0el4DUSzRw

  20. After reading many of the comments I can say that you young Lady amaze me also and do your parents proud. Better watch out for the guy’s though, they will be wanting you to do all the repairs on there cars. It does my heart good to see young people that want to learn more than one thing. My Father told me not to put all my eggs in one basket, learn all I could so I could be an asset to an employer or for my own business.

  21. Cool project Hannah! Only thing I would suggest is wear a leather boot of some type. Hot sparks in the feet mean the burning foot dance. Can wait to see it finished!

  22. Hannah, you are an inspiration to many men and women who would love to aspire to your skills and a true model of diversity, well done. The filming is also good but if it was possible to have a bit more light on the job in some of the shots it would be even better.

  23. Nice work Hannah! As you well know, you are an inspiration! Not sure if you use an oxy/acetylene torch but check out MagneGas2 at MagneGas.com. You may be near a welding supply store that carries it. It's cheaper than acetylene and much safer and much hotter. Fun to work with. Check out this amazing technology, I think you would find it as fascinating as I do. Great vids! Keep it up!

  24. Thank god!!! There really is hope for this generation! Most young people these have never used a screwdriver. Excellent work young lady!

  25. Congratulations you can be proud. On Youtube we often see geniuses and gifted youngsters in music and other arts but this time it's in manual work. Don't give up you found a passion and it's easy to see that you like to share and teach. Thank's

  26. Congratulations young lady. Keep up the good work. And those welds are really good. I hope that you have learnt how to TIG weld aluminium.

  27. wow that's one awesome kid,bless her heart wish mine had wanted to learn about about repair or even mechanics,keep up the good work your bug is going to be really cool

  28. Brilliant !! With these skills you could probably get a job at most any auto body of your choice if you wanted, but I'm sure you're too smart for that, take it from a wore out 30yr. Auto body tech. veteran. Some advice though? Check out 3m metal bond epoxy, it'll change your life!

  29. Hello Hanna. Great videos if you ever like a job in a classic mustang restoration shop you can have one at my shop love what your doing keep up the good work

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