Project Warhead

[Wittsend]

I had a difficult time when I made/welded the floors in my Corvair. Even using press plates, clamps and weighted levers I found a 1 second (or less) weld warped the floor enough that I had to wait 3-4 minutes to do the next weld. And I was using my 100 amp Lincoln MIG on the lowest setting.

[rob289c]

Good to see you're on it.  Where did you get that section of floor?  Nice piece of material to work with. You have some big gaps to close up and you'll get a lot of practice doing it!  Keep us posted of progress.  I think I'm done with anything substantial on my project unless we get a sustained warming trend.  Happy New Year!

[1972 Wagon]

Great way to start the New Year! Looking forward to your progress updates.

[warhead2]

Ok first update of 2025. Didn't post last wk because my Farther n law is in the Hospital with pneumonia but he is getting better.
So I finally started a few tack welding in the drivers floor pan. I used 1 sheet metal screw to help hold pan down. Got a few spot welds after trimming the pan a little more and drilling some holes for spot welds. Only one picture this time.

[rob289c]

Looking forward to your progress and glad it's not me doing floor work!   

[warhead2]

Yeah I definitely know about that welding trick, but good reminder
This has got me motivated. And excited to work on the
Floor pan this wknd. I still need to grind my welds
Down. I definitely will keep everyone updated.
I'll try and post more pictures this Sunday of my progress.

[rob289c]

Looking good... Practice makes perfect!  When I did my Mustang floors I had to replace the entire passenger side including some of the toe board, but the driver's side wasn't as bad so I only cut the bad parts out and sectioned in the parts of the new panel that was necessary. 

Some advice in case you are interested...when welding the sections in, don't try to run a continuous bead without stopping the trigger.  Trigger a spot at a time to let the puddle settle, then quickly hit the puddle with another quick trigger, and continue.  Warpage isn't as much a problem on the floors as it would be on a quarter panel so you can probably do a couple of inches at a time in between machine "rest periods". I'm no expert, but I've picked up a few tricks welding on junk cars through the years! 

Keep posting to keep us engaged.  I haven't done anything to my project in about a month.  I want to install the grill in the front surround then mount it on the car.  I did install the bumper/headlight mounts but I don't think I submitted a debrief report.  I may do it this weekend even though it is going to be frigid this weekend!

[warhead2]

Got some more bad metal cut out and got this toe board
Welded in. Noticed that the metal strip over the
Frame rail was not that badly rusted so I left
It. One step closer to getting in my bigger floor pan in.

[rob289c]

Brings back memories of when I was patching my rotted floor.  Mine was the same orange color.  Keep it going...every little bit gets you closer to completion.  And you will improve your welding skills with more practice.  It's not easy when you have to weld on Swiss Cheese rotted metal. 

[warhead2]

Pic of what I welded

[rob289c]

Keep it going!  I like to read others posts.  Send pics when you can.

[warhead2]

Small update, haven't did much since last post. But worked  on the drivers floor pan and toe board. Cut out some of the toe board and welded in a small piece and ground it down. Hopefully  will get more done this weekend. But Tapatalk is not working cant log in so can't post some pics

[rob289c]

I just rolled my welder under the bench this AM.  I'm hoping I don't need to use it for a while!  I need to focus on all the little things my project needs to get it ready to run and drive. 

[warhead2]

Thanks.   Got some more grinding done but forgot to take a picture lol. I bought a bandfile Belt Sander to help get into tight areas. Works really well sanding down the welds. Also worked on the battery tray, used an metal bar and body hammer to fold the metal. Got it welded in ,still needs more but it was late so called it a nite


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[rob289c]

Practice makes perfect, or in my case...practice makes acceptable after a lot of grinding, body filler, primer and paint!     Keep on going.  Git 'er done!

[warhead2]

Got the rest of the metal cut out. Used an old office folder to make my template and cut out my new metal. I then trimmed it little bit at a time till it fit, and got it welded in not all the was done on this patch. Also while removing the horn bracket bolt got hard to turn then twisted off the metal so another sheet metal repair lol.
But its not too bad.

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[rob289c]

Glad to see you're on it.  We need to read more than my long, drawn out stories!     I use a pneumatic cut off tool.  It does allow tighter access than a 6" cutting wheel.  You will go through a lot of discs,  You'll be an expert metal worker by the time you have completed your project!  Keep going...

[warhead2]

Small update bought me this Ryobi cut off tool. It works really great. Also great option if you don't have an air compressor that can feed heavy air tools, also easier to control than a grinder with a 6in cutting wheel.
Was able to get into a few tighter areas that I couldn't get with the grinder.  First pick is just forward of the battery tray near the horn. Need to remove horn and finish my cut. 2nd picture i cut out the spot drivers side trans hump. Hopefully have more updates soon

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[warhead2]

Oh yeah I broke the curse lol.   Yeah I have had that problem of blowing thru, I set it low and just send it sometimes lol but it's not too bad could be the metal is still too thin and I should have cut it back more. But ill grind it down so it looks somewhat better and paint it.

Heard some good advice a few yrs ago from Gearz Stacey David  that when you fell overwhelmed by your project just set and do small goals and complete the small goals and before you know it you have alot done.

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[alwaysFlOoReD]

I wish there was a like button on this forum.

[rob289c]

I'm glad to see you've made progress.  I will be posting some small steps I made on mine this weekend.  Keep going...don't give up!

[Wittsend]

Congratulations! After 15 days without a new post here at the PCCA you broke the curse.


Frankly I don't know how people get nice welds working with old sheet metal. I'll grind off ALL the paint and rust on both sides, wipe it down with acetone, back it with a copper plate if it seems necessary and on one setting the weld will pile up and show little penetration. Then at the next higher setting it will repeatedly blow holes in the metal (which is why I backed it with copper). It is like you can't win. As you said, no one will see it.

[warhead2]

Small update got my battery tray area welded 98% just have a few pin holes to touch up and grind my welds. Its not pretty but its not going to be visible to anyone. Plan on getting the Ryobi 3in cutoff tool in the next wk which will make cutting metal easier than a grinder with cut off wheel. Small progress but its progress

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[warhead2]

My tank is 80 CF almost 3ft tall 32in. Yeah after this mess up I'm definitely checking it twice. Also I'm in Oklahoma,  so not alot of BS fees added on for refill.


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[Wittsend]

I just got my welding Co2 tank filled back up after I made the mistake of leaving it on. I welded one wk came back a wk later went to turn the tank on and was like why is it so hard to turn on? Then it hit me to try and turn it the other way. I'm not going to make that mistake again. Luckily its not a very expensive one only $35 to fill back up. 

How big is your tank? Mine is roughly a 6" diameter and 24"" tall (less the valve). Back in 2020 it cost me  $62 for Argon/Co2. Here in California a bit more than half that cost is the gas itself, the rest are "fees." But, yea, I HATE when the tank is left open. Talk about "throwing your money to the wind." Now I close the valve and check it at least three times and then every day for about three days after. The good news is that (assuming I have closed the valve) I get well over 5 years out of a tank, but that is also a testament to what I'm NOT getting done.

  I just got my welding Co2 tank filled back up after I made the mistake of leaving it on. I welded one wk came back a wk later went to turn the tank on and was like why is it so hard to turn on? Then it hit me to try and turn it the other way. I'm not going to make that mistake again. Luckily its not a very expensive one only $35 to fill back up. 

How big is your tank? Mine is roughly a 6" diameter and 24"" tall (less the valve). Back in 2020 it cost me  $62 for Argon/Co2. Here in California a bit more than half that cost is the gas itself, the rest are "fees." But, yea, I HATE when the tank is left open. Talk about "throwing your money to the wind." Now I close the valve and check it at least three times and then every day for about three days after. The good news is that (assuming I have closed the valve) I get well over 5 years out of a tank, but that is also a testament to what I'm NOT getting done. 

Oh, and also, YET AGAIN I type in the typing pane and it shows as a 10 point font (I left it to be seen - or better said not). Yet when it posts it is tiny to the max! I have to copy the whole text, reset it to 10 point and only then is it correct.

[warhead2]

Not alot to update on, haven't done much. Just little more underside cleaning then primer then undercoating.  Also cut out this piece of rust under the passenger backseat area.  I just got my welding Co2 tank filled back up after I made the mistake of leaving it on. I welded one wk came back a wk later went to turn the tank on and was like why is it so hard to turn on? Then it hit me to try and turn it the other way. I'm not going to make that mistake again. Luckily its not a very expensive one only $35 to fill back up. 

Now I have it filled back up I can start welding again. Yay. Thats all for now

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[warhead2]

Glad to see you're still on your project.  I almost sent a reply over the weekend to see if there were updates.  I figured you'd let us know when you had something to post so I didn't bug you.  You had the motor apart...how did that end up?  I am trying to get enough other things done on mine so I can try to start it before I have to put it away for the Winter.  I don't want to leap frog other tasks and get the project out of synch.  I really want to hear it run after getting the timing spot on.  It should be better than it was when I got it!

Keep going and keep us posted.  We learn from each other...

Thanks Rob I haven't done anything else with the motor yet. I want the block dipped cleaned and possibly get the block n head milled possibly just so its even. But if I do that I'm not sure what all I need to do, because it Changes things. I'm no expert on rebuilding engines, I understand the basics. I have a friend that is a certified mechanic that I'm going to ask for his help.
Don't be afraid to ask questions your not bugging me, I've been trying to work on it every Friday and Sunday now that the temps are cooling off will be more pleasant to work on it maybe get more done. My goal is to have it running by December 31 but not done or street legal.

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[rob289c]

Glad to see you're still on your project.  I almost sent a reply over the weekend to see if there were updates.  I figured you'd let us know when you had something to post so I didn't bug you.  You had the motor apart...how did that end up?  I am trying to get enough other things done on mine so I can try to start it before I have to put it away for the Winter.  I don't want to leap frog other tasks and get the project out of synch.  I really want to hear it run after getting the timing spot on.  It should be better than it was when I got it!

Keep going and keep us posted.  We learn from each other...

[warhead2]

Sry haven't updated in several months. Got some welding done on the battery tray area. I know its not pretty but don't have a work bench or vice to help with bending metal. Its slow but I'm getting there

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[warhead2]

Another small update removed the inner fender battery plate drilling out the spot welds and help from an air chisel. Getting closer to start welding. This will be my first patch of meny.

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