i just got done puttin a handle relocator on my tailgate, an it warped when i welded it. i even used compressed air to cool the spot welds... i thought i had done it good untill i was done is when i noticed it anyways i tried to pull it out but it just pops back down, is there anyway to fix this without using a ton of bondo??? also there any tips on warping?

 

First off what kinda welder did you use 110 or 220. What size wire? I am assuming your using a Mig. Did you use Gas mix?

Welding thin sheet metal is pretty easy, but time consuming. You stitch weld the pieces together. Basically very small tacks laid side by side. You only want to do 4-5 tacks in one area, then move to down the panel far away, then do 4-5 tachs, then move again. 4-5 tacks should only be like .5 inches long. NEVER run a complete bead... Doing the small tacks spread out over the entire panel helps keep the metal cool. You really don't want it to cool to quick, like using compressed air or water to cool it cause it will warp, sorry. YOu want to use a smaller wire too, with a lower heat seating...

example of stitch weld


Also notice the heat burns are even on the entire weld, this is important, because if it is not consistant or spikes, then you put to much heat in that area which will warp it.

another example, notice the heat burns.




All those were done with a Licoln 220 with .025 wire and gas...

 

i used a gas lincon 220 mig with .023 wire... i guess i just got carried away. any suggestions on how to get the warp out? i just like a big dent, i dont really want to have to use a ton of bondo..

 

You could try heating it up with a torch then using a cold wet rag to cool it rapidily to get it to pop back out. or cool it with ice or dry ice. I have never tried any of those put I have heard of people doing it. More than likely you need to knock it out with a hammer or a dent puller, Bondo over 1/8in thick is toooo much, escpeically on a moving part like the tailgate...

 

dry ice might work?

watch this..

 

i tried a dent puller,it just goes back in.. i think im going to try to heat it up an use a cold rag, hopefully this will work, as the warp is about 1/4in deep thanks for the tips BlackGMC

 

No problem man, sorry your having problems. One thing you could try as a last ditch effort is to cut it out and redo it.....

 

lmao thats pretty good dont know if id try it on my truck

 

intresting... might try this mine qualifies as the big dent

 

just throwing it out there as another option.