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Guest Message by DevFuse
 

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Alfa 156 sportwagon - very slow progress

Oh shit

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132 replies to this topic

#121 OFFLINE   chodweaver

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Posted 07 March 2017 - 11:37 AM

Might try to skive off work and show up if you're not already oversubscribed? Could even bring some tools...

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#122 OFFLINE   320touring

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Posted 07 March 2017 - 02:06 PM

I can buy you a commiseration pint tonight if needed?
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#123 OFFLINE   Dave_Q

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Posted 07 March 2017 - 03:55 PM

Might try to skive off work and show up if you're not already oversubscribed? Could even bring some tools...

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Not at all, send me a PM I will send you my number and some details, thanks. Am vaguely OK for tools but the more the merrier.

 

 

I can buy you a commiseration pint tonight if needed?

 

I'll take the pint but commiserations not required, I'd rather have a rusty Alfa than a Skoda of any description. :)


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#124 OFFLINE   Dave_Q

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Posted 09 March 2017 - 07:01 PM

Some progress did occur today, but the retest tomorrow is looking unlikely.

Here is the final amount cut out, note approx 1 sq.ft floor missing in background.

1307ec6127d5e4a64d5de1adfcf8bac5.jpg

cf2e07c3aa9f0be5429a86b94e481f1a.jpg

Shortly after this the excellent Mr Chodweaver came along, provided moral and technical support on the welding, and even said reassuring things about the sanity of spending hours welding up a pretty worthless car.

f96ae6f1903fe437e941a7b4ad76562e.jpg

Welding looks rubbish but is strong, obviously still not finished but well on the way.

MOT ETA about May.
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#125 OFFLINE   chodweaver

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Posted 10 March 2017 - 12:24 AM

My absolute pleasure to meet you and be able to provide a little assistance, Mr Q. Let me know when you will be attacking it again and I'll try to arrive earlier and stay longer, not to mention be more organised with what tool I put down where.... :-D

 

I meant to ask - how did you form the patch to the shape required to fit round the sill? It looked much better than my attempts at a nice, uniform curve but then I haven't advanced beyond the use of hammers, plumbers pliers and a vise. Did you enlist a lamppost?

 

NB I am not to be relied upon for balanced, objective advice where shite and its salvageability is concerned. If it looks less rusty and more likely to pass an MOT than what I'm driving, then of course it's worth doing. Plus, Alfa. I wish my heaps were as clearly so far from the bridge.


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#126 OFFLINE   Dave_Q

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Posted 10 March 2017 - 10:11 AM

I formed the lip by hammering it over the edge of a square piece of wood and just bent the top edge with mole grips.

 

It's not quite* factory shape but as discussed it's getting wobbed over with an inch of underseal then covered by a plastic sill, so hopefully the concours judges won't notice.

 

For the next section I will make sure the patch overlaps all the way round (as mentioned upthread by a man who clearly knows more about welding than me) and actually remove all the paint beforehand - hopefully this will bring an improvement in results.


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#127 OFFLINE   chodweaver

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Posted 10 March 2017 - 11:04 AM

^ That it turn reminds me of two further tips that I picked up:

 

1 Immediately after applying a tack, tap the area tacked with a hammer - this helps to reduce stresses arising from the heat of the tack, and lessen distortion as the weld and surround cools

 

2 Cut your holes and your patches with curves at the corners, rather than sharp 90deg (so, like a bike puncture repair patch). Again, this reduces a localised build up of heat at each corner and lessens distortion in the patch.

 

And, my crappy welder has the OE torch on it with such a crude trigger action that the gas comes on a good few mm in the trigger movement before the wire feed and current. This means I can flood the area with weld gas before the arc starts and I've found this helps me get a cleaner weld. Your mig does seem to perform rather better than mine anyway, but if there is a way of getting the gas to flow sooner, I would make use of it.


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#128 OFFLINE   Hooli

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Posted 10 March 2017 - 12:31 PM

 

 

1 Immediately after applying a tack, tap the area tacked with a hammer - this helps to reduce stresses arising from the heat of the tack, and lessen distortion as the weld and surround cools

 

 

Why does that work?



#129 OFFLINE   chodweaver

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Posted 10 March 2017 - 02:54 PM

I don't know! But the guy who told me is a professional welder - not just of cars, that has just been a hobby of his for many years - but of proper big scale stuff. I believe he worked on the chassis of the Millenium dome/O2 arena. So I tend to think he knows what he's talking about.



#130 OFFLINE   Dave_Q

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Posted 25 March 2017 - 09:16 PM

I'm still plugging away at welding this up, a couple of hours a week.

 

In the process I feel my welding has progressed from appalling to slightly less appalling.

 

2017-03-23 21.14.07.jpg

 

2017-03-23 21.14.31.jpg

 

I'm quite enjoying making up repair panels, I'm fairly proud of this sill end I made with cardboard templates and hammers.

 

2017-03-23 21.41.48.jpg

 

2017-03-23 22.03.02.jpg

 

Have also discovered some crust in the bottom of the front wing on the same side.

I could weld it up but I'm probably going to go for tactical gaffer tape.

 

2017-03-23 21.13.39.jpg


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#131 OFFLINE   chodweaver

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Posted 26 March 2017 - 12:35 AM

That sill is coming together nicely! Good stuff.

Shout if you need some more well intentioned bodging from me

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#132 OFFLINE   PiperCub

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Posted 26 March 2017 - 10:44 AM

I don't know! But the guy who told me is a professional welder - not just of cars, that has just been a hobby of his for many years - but of proper big scale stuff. I believe he worked on the chassis of the Millenium dome/O2 arena. So I tend to think he knows what he's talking about.

 

I've been told this too, likewise, I don't know the physics as such but can guess it's to do with reforming (or 'massaging the metal' as my mate referred to it as) the heated and therefore expanded metal  back into it's previous structure at a (probably) molecular level, hence returning the metal to it's original more neutral state. (Yes, I am guessing somewhat here!!). Having said that, I usually forget to do it anyway so not sure how effective it is. 

 

 

 

Boring factiod No.118: I used to work at the Millenium Dome too! Given the structure is still up, I can assume your friend wasn't one of the many builders smoking weed all day that I encountered!



#133 OFFLINE   Dave_Q

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Posted 29 March 2017 - 09:56 PM

Sill pretty much done, I ran out of gas at the end.

 

2017-03-29 21.59.37.jpg

 

Definitely starting to get the hang of this welding lark, so much so I feel I can share my TOP TIPS for beginners trying to MIG their heaps through an MOT.

 

 

1. Clean the metal you are welding to - you can't weld to paint.

 

2. Spend longer making patches and make sure the surfaces you are welding are touching all the way round - you can't weld to air.

 

3. Overlap your patches - that TonyBMW guy on the blue forum can butt weld 0.8mm italian gauge steel - you can't.


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Assorted pushbikes





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