MY Wagon Rust repairs

revmax · Post by **revmax** » Fri Aug 10, 2012 4:08 pm

This thread is all Bennies fault.

But I am gunna fix it.
First repair rear quarter.

Post by **TOONGA** » Fri Aug 10, 2012 6:11 pm

Is that the left rear area where the mudflap should be?

good luck with the fabrication, lots of metal shaping and welding to come.

TOONGA

revmax · Post by **revmax** » Fri Aug 10, 2012 6:15 pm

yep.
too late to grind and blend it, cause it is dark outside now.

steptoe · Post by **steptoe** » Fri Aug 10, 2012 6:48 pm

Love the workshop floor

Silverbullet · Post by **Silverbullet** » Fri Aug 10, 2012 7:37 pm

Fantastic! Looking forward to seeing more of this kind of work, since I'll be doing something similar. Questions: What thickness steel are you using? MIG welding it? what current do you go down to for this thin steel?

Keep the pics coming

revmax · Post by **revmax** » Fri Aug 10, 2012 7:48 pm

SB The steel sheet, I think is called zincalume is 1mm thick.
Gassless mig has 6 power settings, for this stuff set on 1 and adjust wire feed to suit.
on 1 it is too powerfull to do a constant run so I just pull the trigger for a second wait another second, kinda pulsing the weld, once ya get going it can work well.
I am only doing a rough job to be structualy sound for reregistering it some time soon.
LOTS more cutting has to be done on the under side of this poor old wagon.

Silverbullet · Post by **Silverbullet** » Fri Aug 10, 2012 7:56 pm

Yeah the white powdery stuff gives the zinc away

I've heard pulsing the welder is better for panels rather than running a continuous pool, less heat/distortion etc.

Post by **TOONGA** » Sat Aug 11, 2012 11:53 am

looking good

only a square metres worth to go

got to love those wagons

TOONGA

Cliff R · Post by **Cliff R** » Sat Aug 11, 2012 4:21 pm

Gasless is great but from memory when I was doing up a 1970 VW notchback (didnt finish it unfortunately) I had to basically tack weld panels cos the smallest gasless wire was 0.9mm diameter and it definately blew holes in the weld run. If the MIG is a gas/gasless with the 0.6 it is heaps better. I used the 0.6 with a small disposable Argon mix can so I didnt have to hire an expensive D size Argon cylinder.

revmax · Post by **revmax** » Sat Aug 11, 2012 5:00 pm

Yer I'mm gunna have to get more sheet.
Cliff thanks for the tip I have one of those bottles and some wire but will save them for something more important.
If ya have a look at the piece I welded in you can see on the edges I put a backing plate on the edges to take some of the weld.

OK jobs done.
Had a look at and adjusted the rear drum on this side as i had to take the wheel off to drill new holes for the mud flap.
OH the white is just saturn white from a pressure pack

Post by **TOONGA** » Sat Aug 11, 2012 6:24 pm

very nice and those rear brakes look brand new.

TOONGA

Cliff R · Post by **Cliff R** » Sun Aug 12, 2012 1:45 pm

Looks great, good work. my MY needs new rear shoes and wheel cylinders as the fluid has leaked onto the pads and they stick and are noisy.
Dont forget the right regulator when using the gas wire and disposable bottle either.

revmax · Post by **revmax** » Sun Aug 12, 2012 5:57 pm

Toonga yer they look like they havent done much.
Cliff I have a reg and a dispsable gas bottle, Have only used it on Aluminum though.
Gasweld has some 0.8mm flux core wire and as i just ran out I will get some from gasweld tomorrow.

done heaps of repairs today but forgot to take a lot of photos.

This one was blasted last week.

Cardboard template made.

Steel cut welded in place, dillberrys ground off, smear some seam sealer around and drill the hole.

revmax · Post by **revmax** » Sun Aug 12, 2012 6:06 pm

AHHH remember this one.
Managed to cut the rust out with a 5" makita angle grinder, it is 5" but has a 4" motor which makes it ideal for getting into tight spots. The cutting wheel was one of them 1mm thick ones.

Got the metal stiched in but ran out of wire, the welds were a bit like duck poo and I am thinking I should have used my shorter 15A extension lead that I used earlier in the day.

YouTube · Post by **El_Freddo** » Mon Aug 13, 2012 5:19 pm

Looking good there mate! Much more rust or is this just the tip of the iceberg?

revmax wrote:This thread is all Bennies fault.

My pleasure

steptoe wrote:Love the workshop floor

It should be good in summer!!

Cheers

Bennie

revmax · Post by **revmax** » Mon Aug 13, 2012 6:38 pm

Bennie, yer she has a whole lot of rust and if we get 12 months of fun out of her I will be happy. I can see more rust when i look up the holes in difficult spots most of it doesen't look structual but I am sure it will later down the track as I plan on driving this one on beaches it hasent got much of a chance.

The work shop floor got wet friday night so I laid on cardboard for the repairs.

Got some more wire today but probably won't get to her till later in the week.

revmax · Post by **revmax** » Sat Aug 18, 2012 12:39 pm

ah that side is almost done
used a broom handle shaped to bend the sheet onto place then used a pneumatic chisel with the end ground down to a ball to peen the metal into the corner.

alang · Post by **alang** » Sat Aug 18, 2012 2:08 pm

Bunnings has the gasweld wire in 0.8 gas less as well and i think supercheap has come on board to good to price around some times. the repairs are looking good

revmax · Post by **revmax** » Sat Aug 18, 2012 5:53 pm

Yer but the blokes at Gasweld know what they are on about and if I have a question to ask they will answer it. Try to get an answer from staff at Bunnings or supercheap. Yer right!

alang · Post by **alang** » Sat Aug 18, 2012 7:50 pm

your right about the no help policy, just thinking of the running cost the closest gasweld to me would be like driving from coff's to bonville and passing bunnings and supershit on the way

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MY Wagon Rust repairs

MY Wagon Rust and other repairs ready for rego.