I've been welding new floor pans in and I can never seem to get the weld consistant all the way around.

It looks good...I grind the welds... but when I shine a light from underneath, I see little pin holes of light.

It's driving me crazy.

What am I doing wrong?

I am eventually going to attempt quarter panel skins, and I'm feeling if I can't get floor pans right, how the hell am I going to have nice welds on the quarters?

Are you using gas or flux core

There are plenty of variables to ask if your doing, so really its hard imo to reply to your situation.

All I can do is toss out some basic rules:

When stitch welding you lay down a bead only 1-2 inches then move to another spot, this helps keep the heat down. To much heat means metal warp. Do not rush it use two hands keep it steady and slow. You want to make sure you get good penetration and do not overheat the metal.

The basic process of laying a bead is not too difficult. You are trying to make a small zig zag with the tip of the welder, or little concentric circles moving your way from the top of the weld downward. I like to think of it as "sewing" motion where I use the tip of the welding gun to weave the two pieces of metal together.

I like to keep the welder held about 20 degrees and push my welding tip forward -vs- pulling it along. This keeps the shielding gas on the area I am welding, where as if I pull it the gas is being blown onto the area I just finished.

If I am welding a quarter or really worried about metal warp I zap solid tack weld then move 6-7 inches and repeat all along the section needing welding, and come back to the first sot and lay one right beside the first. This will be the most common chance of getting holes between your welds in my experience. I just try to get as close to the existing weld as possible.

If you are laying down lots of short tack welds..which is a good idea....invevitably you will get some pin holes. Don't fret. What I have done is shine a light from behind before I grind anything and touch up the ones I see then. If I have many siginificant ones after I grind then I touch them up with a few more spot welds and regrind. Lastly, a few tiny pinholes are not a real big deal but be certain to put a waterproof ( like All Metal) body filler. It is recomended to use that type filler on all exterior welds...wether you see pin holes or not. Just remember to spot weld as many as you can before you start welding. Another little trick is to try to strike an arc with each new weld on a previous weld. Good luck

Clean metal, good grounds reasonabley close to the weld area, clean metal, dont hold the tip too far away as it looses current (heat) rapidly with just a few millimeters, clean metal helps a bunch too... ;)

How are you holding the panels together befor you weld them? "Cleco's" (I think thats how they are spelled) are the cats meow when it comes to aligning and holding panels together before welding. They are cheap on E-Pay.

Got any pics of the areas in question? Would help alot as far as getting the help needed to isolate the problem...


Chris:cool:

I am using gas and holding the metal together with "Butt Weld Clips".

I like the idea of pushing as opposed to pulling the weld (I was told to pull).

I think I'm doing it right, it just seems like it's taking forever to get a solid weld.

I know the "proper" welding technique is to push........but I have always pulled and can weld just fine with no issues. When I try to push, my beads are inconsistant. Also when I weld, I blow the bead back into itself with half semi circles......looks like I am almost making an upside down U........just not quite as much of the sides and more of the top of the U. Did that make sense?

http://www.expertvillage.com/video/7637_welding-push-pull.htm?ref=yssp

"I think I'm doing it right, it just seems like it's taking forever to get a solid weld."

Take your time, and go slow... so when dealing with a large section to weld up it can/should take some time. Speed kills!

I am eavesdropping here since I am also about ready to try my hand at installing a quarter panel. Very good advice! About the Cleco's, how much overlap do you use or is there some way to use them to butt weld? I have read that butt welding is the right way but it seems that an overlap would be stronger. I could use some assistance here.