First attempt at real bodywork. Tips?

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moparmandan

moparmandan

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I've done floor pans, trunk pan, drops, inner fenders and straight line quarter panels.etc. Where it's easier to get away with some beat to fit, paint to match. This is my first time doing something more difficult like rust r&r in an a-pillar. I'm trying to avoid pulling the dash and glass. Have removed the rust back to good metal.
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My first question is will a copper sheet between the dash and a-pillar protect me from welding the a-pillar to the dash? LOL
I'm thinking slow and easy, Keep everything nice and cool. Do a spot weld, let it cool really well. Do another. Inside patch first, work my way out. Weld thru primer will be used for sure. Here's my donor.
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Any comments or tips will be much appreciated!
 
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Oh yeah, my son's 1973 Scamp. Previously a vinyl top car. :(
Thanks!
 
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Those a pillars are layered as you know.so at our shop we would start with that inside piece by the dash.just jam a piece of scrap metal behind it and weld it from the inside so the weld would be covered when you attach the outer piece. Once you got the inner pieces looking factory primer the inside cavity and lay the outer piece on top. Trace it with a sharply where you want it and then trim the car to fit the ppiece.it's easier then shaping the piece and shooting it across the room lol.The tighter the fit the easier it will weld. If using a tig get some .020 wire .it wont shoot holes in that thin metal .put a tack every 1/2inxh or so, and clean it well with a wire brush often as you do it. The only other advice I have is to keep an eye on the urethane around the windshield. It doesn't take much heat to make that stuff melt and drip where you dont want it. Oh ya put some seal seal around it after so it doesn't ever leak again
 
Cool Hand said:
Those a pillars are layered as you know.so at our shop we would start with that inside piece by the dash.just jam a piece of scrap metal behind it and weld it from the inside so the weld would be covered when you attach the outer piece. Once you got the inner pieces looking factory primer the inside cavity and lay the outer piece on top. Trace it with a sharply where you want it and then trim the car to fit the ppiece.it's easier then shaping the piece and shooting it across the room lol.The tighter the fit the easier it will weld. If using a tig get some .020 wire .it wont shoot holes in that thin metal .put a tack every 1/2inxh or so, and clean it well with a wire brush often as you do it. The only other advice I have is to keep an eye on the urethane around the windshield. It doesn't take much heat to make that stuff melt and drip where you dont want it. Oh ya put some seal seal around it after so it doesn't ever leak again
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I meant seam sealer damn auto correct lol
 
Cool Hand said:
Those a pillars are layered as you know.so at our shop we would start with that inside piece by the dash.just jam a piece of scrap metal behind it and weld it from the inside so the weld would be covered when you attach the outer piece. Once you got the inner pieces looking factory primer the inside cavity and lay the outer piece on top. Trace it with a sharply where you want it and then trim the car to fit the ppiece.it's easier then shaping the piece and shooting it across the room lol.The tighter the fit the easier it will weld. If using a tig get some .020 wire .it wont shoot holes in that thin metal .put a tack every 1/2inxh or so, and clean it well with a wire brush often as you do it. The only other advice I have is to keep an eye on the urethane around the windshield. It doesn't take much heat to make that stuff melt and drip where you dont want it. Oh ya put some seal seal around it after so it doesn't ever leak again
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Awesome! Thanks for the help! I'm using a mig, I'm assuming you recommend the .020 wire for that?
 
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You are doing great!!! I didn’t have to work around my dash but there are good comments here. Keep a spray bottle near and/or compressed air to cool
 
JMO- If it's your first attempt at something like this, you may be Flirtin' with Disaster (forgive the Molly Hatchett reference). I would at the very least pull the dash pad. It's a pain in the patoot, but it could save you days of banging your head on concrete walls while spewing out four letter words you didn't even realize you knew... The worst has a tendency of happening when you try to take the easy way out. Dressing/finishing the weld on the interior will also be almost impossible, but that area will be covered by the A pillar trim. Welding spatter tends to go places you never planned, and have effects you didn't foresee. I'm sure BP has it down to a science, he's a pro- but I wouldn't trust myself on this, and it's not my first time at the dance. Even the windshield, no matter how well you think you have it protected, if you get even a little spatter that finds it's way through, you'll be staring at it every time you get behind the wheel. Re-commence head banging. I once was welding (carefully, so I thought) a c-pillar seam and blew out a rear window- wasn't even near it... probably a freak occurrence, but why tempt fate?
Ultimately, it's your call. Feel lucky?
 
Cool Hand said:
The only other advice I have is to keep an eye on the urethane around the windshield. It doesn't take much heat to make that stuff melt and drip where you dont want it.
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You probably meant butyl instead of urethane too. I've never seen burning urethane drip but boy does it stink. Gotta be a real killer.
 
Professor Fate said:
JMO- If it's your first attempt at something like this, you may be Flirtin' with Disaster (forgive the Molly Hatchett reference). I would at the very least pull the dash pad. It's a pain in the patoot, but it could save you days of banging your head on concrete walls while spewing out four letter words you didn't even realize you knew... The worst has a tendency of happening when you try to take the easy way out. Dressing/finishing the weld on the interior will also be almost impossible, but that area will be covered by the A pillar trim. Welding spatter tends to go places you never planned, and have effects you didn't foresee. I'm sure BP has it down to a science, he's a pro- but I wouldn't trust myself on this, and it's not my first time at the dance. Even the windshield, no matter how well you think you have it protected, if you get even a little spatter that finds it's way through, you'll be staring at it every time you get behind the wheel. Re-commence head banging. I once was welding (carefully, so I thought) a c-pillar seam and blew out a rear window- wasn't even near it... probably a freak occurrence, but why tempt fate?
Ultimately, it's your call. Feel lucky?
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Only burned one car to the ground. lol. OK it was just a top on a Miata. 800 bucks though. :BangHead:
 
Professor Fate said:
JMO- If it's your first attempt at something like this, you may be Flirtin' with Disaster (forgive the Molly Hatchett reference). I would at the very least pull the dash pad. It's a pain in the patoot, but it could save you days of banging your head on concrete walls while spewing out four letter words you didn't even realize you knew... The worst has a tendency of happening when you try to take the easy way out. Dressing/finishing the weld on the interior will also be almost impossible, but that area will be covered by the A pillar trim. Welding spatter tends to go places you never planned, and have effects you didn't foresee. I'm sure BP has it down to a science, he's a pro- but I wouldn't trust myself on this, and it's not my first time at the dance. Even the windshield, no matter how well you think you have it protected, if you get even a little spatter that finds it's way through, you'll be staring at it every time you get behind the wheel. Re-commence head banging. I once was welding (carefully, so I thought) a c-pillar seam and blew out a rear window- wasn't even near it... probably a freak occurrence, but why tempt fate?
Ultimately, it's your call. Feel lucky?
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Thanks for your comments and I don't mind the Hatchet reference at all. You know, Florida boy and all. You have touched on some of my major concerns. The dash pad is definitely coming out at the very least. It's trashed and has a plastic cover anyway, but why chance it? Pulling the glass and the dash is a whole 'nother story. Obviously, it is definitely the best way. And I have advised the car's owner, my son, about it. He thinks we can get enough cardboard and welding blanket around the rest to protect it. Hmmmmm........
 
The only advice I have is go slowly and take your time. You have no deadlines, so don't rush it.
 
RustyRatRod said:
The only advice I have is go slowly and take your time. You have no deadlines, so don't rush it.
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You got that right. His first response when we found the rust, well it's been like that this long. I said yeah but we didn't know about it. And now that we do, we gotta fix it. I can let some things ride, but a rusty a pillar is unsafe. If it's mine, that's on me. My kid? No way. Car is down until this is fixed. He gets it.
 
missing linc said:
It's always surprising where those welding sparks will find their way into, definitely be careful with the windshield.
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And the end of the day. I hate welding toward the end of the day. I can't sleep until I go back to the shop and make sure nothing is on fire.
 
moparmandan said:
You got that right. His first response when we found the rust, well it's been like that this long. I said yeah but we didn't know about it. And now that we do, we gotta fix it. I can let some things ride, but a rusty a pillar is unsafe. If it's mine, that's on me. My kid? No way. Car is down until this is fixed. He gets it.
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And I thought all the people who think the way I do were extinct......
 
moparmandan said:
You got that right. His first response when we found the rust, well it's been like that this long. I said yeah but we didn't know about it. And now that we do, we gotta fix it. I can let some things ride, but a rusty a pillar is unsafe. If it's mine, that's on me. My kid? No way. Car is down until this is fixed. He gets it.
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You are absolutely right to black flag him until the car is inspected and safe as it can be.

You remind me of when my adoptive dad black flagged my dart off the road because of a corroded brake line when I was kid starting out with cars. Got it fixed and back on the road safely.
 
Princess Valiant said:
You are absolutely right to black flag him until the car is inspected and safe as it can be.

You remind me of when my adoptive dad black flagged my dart off the road because of a corroded brake line when I was kid starting out with cars. Got it fixed and back on the road safely.
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Thanks. He's 20 so I rarely put my foot down with him anymore. I figure he's grown. Dumb sometimes, but grown. Then we watch Roadkill and laugh at some of the dumb **** they do. IDK.
 
RustyRatRod said:
The only advice I have is go slowly and take your time. You have no deadlines, so don't rush it.
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Best advice! I’m new to bodywork and have just jumped in and have been able to get lots done on my 67 Dart by just going slow and not feeling like I have to be done by a certain time. I find I enjoy it more if I take the “what I get done on the weekend is fine” as there is always next weekend! Currently in the passenger roof rail area.

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