Patch Panel Welding, for those who don't use Instagram. Options

[McMark]

https://www.youtube.com/watch?v=1jBHD7lAJfY


Just posted this on Instagram. Timelapse of welding in a patch panel on this 914. This is the hell hole area, the inner fender wall where the battery tray will mount.

I feel the gap between the panels to see if one is higher than the other, then use a variety of hammer and/or dolly to bring the two pieces level. This step is where good welds are made. Without lining up the pieces you'll never get invisible welds.

Then a quick series of tack welds, stacking one onto the next one until the gap is filled. Then hit it with a wire brush (blue handle) to remove the burn 'smoke'.

I use a variety of grinders, but mostly the 3" Roloc 80g sanding disk, to grind the welds smooth. I first shoot to remove 90% of the height of the weld, this is the grinding that makes lots of sparks. Then I lightly grind the last 10%, moving smoothly and evenly and changing grinding direction to avoid cutting grooves/ruts into the material.

Finally some hand sanding with 120g emery cloth which highlights and high or low spots that need further attention.

This video represents about 35m of work. If there's any interest, maybe I'll take a real-time video tomorrow to better show the process.

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