Hey welder people....

[Kats66Pny]

Ok I need someone familiar with welding to help me figure out how to make a good patch panel. It was decided I guess not to do the butt weld as it would be too difficult to get a 100% perfect fit. So I need to figure out how to make a patch because I guess different weld techniques determine what/how to make a patch . 

I'm assuming the guy who will be doing my welding will be doing lap welds (I think that's what it's called lol) which is like it sounds, metal overlapping. If that's the case then....

- Green circles : How much of the end is suppose to overlap? 1/4 inch? 1/2 inch? 1 inch?

- Red arrow : Does that corner need to be flattened to match the angle of the angle under it, or can it just be left as-is and welded like that with that little gap there?



The sooner I can make these patches, the sooner I can get the new cowl in. 

[AzPete]

The closer the patch fits to the cars shape...the better the weld will hold. It will also be easier to weld because the welder is not having to fill holes plus secure the patch. Also, the lap patching style can cause the next piece that lays over that patch to not lay smooth.

Overlap about 1/2" or a bit less. To short of an overlap and it turns into something close to butt welding.

[Kats66Pny]

So which would be best... lap joint or go buy a flange tool and prep it for flange joint? 

[Opentracker]

Depends on how you want it to look. The lap weld will show more than the flange weld.

Abe can show you how to do some nice grinding 

[70_Fastback]

Clamp that piece in place just as you have it.  Grab your grinder with a cut off wheel and cut through both peices (old & patch) at the ends.  Now you have a patch panel the EXACT size you need for butt welding.  Clamp the seems together with vice-grips and tack that thing in.  Grind to fit when it's welded in.

[Kats66Pny]

You will hardly see any of the patch.. it will be covered by the cowl. So it doesn't need to be pretty. 



When I put the new cowl on, it actually lays pretty straight and fits pretty damn good already. 

Clamp that piece in place just as you have it.  Grab your grinder with a cut off wheel and cut through both peices (old & patch) at the ends.  Now you have a patch panel the EXACT size you need for butt welding.  Clamp the seems together with vice-grips and tack that thing in.  Grind to fit when it's welded in.

  Awesome thanks!

[AzPete]

Butt welds make the best look when done as mentioned from the local rat rod builder extraordinaire....

You also should make sure the person doing the welding is in approval of the type of joints he will be doing.

Yes....it needs to be pretty because that makes it functional for the next piece over it.

[Kats66Pny]

I wonder how much it would cost to fly our rat rod building extraordinaire down to Texas and do this for me.  LOL

[silverblueBP]

Just flash him, he'll be down there in 2 seconds!

[Horseplay]

I wonder how much it would cost to fly our rat rod building extraordinaire down to Texas and do this for me.  LOL

Seems he has some issue with airplanes or something...

[Dne']

I suppose you would want the patch piece in as level as the original(only newer), so not to elevate the cowl. However, I think you have the right ideas going on.
 I've never done a cowl, but what's next?
You have to drill a bunch of plug holes for the bottom cowl, then weld the top one to the lower one? or does it all go in as an assembly? Just curious   or What is the sequence?

[Kats66Pny]

I'm going to go by this article -
http://www.mustangmonthly.com/howto/mump_0611_ford_mustang_reproduction_cowl_replacement/index.html

It seems you have to clamp both top and bottom cowls together, punch holes, weld lower to the upper, then weld both (as one piece) on to the car. 

[Kats66Pny]

Here's some pictures that might explain it better.

Picture 1 - The top and bottom cowl are upside down. You can see the little lip that I guess is suppose to be welded to the upper cowl.
Picture 2 - Both cowl pieces in place. You can see how that little lip is underneath.
Picture 3 - You can't see that little lip of the lower piece when both pieces are in place.

[Dne']

Well, that seems simple enough , of course the prep work is a pita!  Kind of gives you a feeling of completion just settig the cowl on where it goes! ; )  I did that with many of my replacement metals~ stand back and admire it before it's actually welded in!  Then over time, it's just a faded memory after all work is completed!

[70_Fastback]

I wonder how much it would cost to fly our rat rod building extraordinaire down to Texas and do this for me.  LOL

Will.  Work.  For.  Paintings...   

[RustyRed]

Just flash him, he'll be down there in 2 seconds!

Or offer to be a welding assistant in a skimpy french maid outfit 

[Midlife]

Or offer to be a welding assistant in a skimpy french maid outfit 

What kind of example are you trying to set for Kat's teenage son?  Shame on you!
















Yeah, a good example!  We'll want pictures, of course!

[abrahamfh]

Abe can show you how to do some nice grinding 

Now I can  . We all start somewhere Kat, and for me, it was at level 0. Thanks to John and Craig I am extremely confident in what I can do now.

Just be patient and take your time. I know you want to get Gert back on the road, but restore it right once and and make modifications forever(while enjoying it that is).