Welds On The Outside And Aluminium Panels
 

Should I grind the welds down on the outside of the chassis for fitting the body panels that will run down the side?

Personaly I would just flatten them a little using a flap disc in a grinder, by the time that you have put the Sikaflex adhesive on the rails that the side pannels touch you will have a nice flat surface ;)

Unless you know for sure that you have a full pentration weld of the welds being fettled you stand a good risk of creating a fracture point if too much weld is removed !!??

Ya I was worried about weaking it by doing it but wasn't sure how people had got round the small "hills" you get where it's been welded (my welding isn't great...). So would you just take the top off but leave say 1-2mm worth of weld?

Yes that's about the sum of it :)

Just flatten it a little making sure that you leave aproximately the materials thickness worth of weld bead.

A good bead of adhesive will most likely be at least 1.5 - 2mm thick once pulled up with a rivet ;)

Nice one, cheers Bonzo :)

I welded some triangular fillets in the corners where the welds needed grinding down for side panels

Do you guys bevel the tube ends to create a valley, then fill it with your weld?

Very fair points chaps :)

MC

I would not have thought that pre-prep of 16 gauge material nessasary if the correct welding current & weld procedure is employed ( That's assuming the correct weld gap is present )

You are right though, if the joints are tight, it certainly would certainly help if you give the joint a quick prep prior to welding any joint that will be ground flush with the surface.


Adrian

Very fair point.

If forming the side panels on the car, yes I can see problems with unsightly welds leaving marks on the panels.

Have to admit, I was a bit blinkered on that one as I formed my side panels on the bench using the pattern given in the book :)

Those panels came out to be a great fit other than the size of the cut out for the steering rack gators being too small ( Still on my to do list )