Welding side sills...any warping?

[piper1112]

Hey Guys,

I posted a while back about heat/corrosion/incompatable metals? that caused my side sills to bubble and in 2 spots bare a hole.I looked at all past threads, but never really saw any comments on welding/ repairing these sills with regards to warping the metal sills. Any comments or suggestions on this repair...my car is to go in tomorrow and I am a little nervous of these sills warping from a weld repair.

Piper

 

[bluesrt]

i know the feeling,try to find a few metal specialist and get all their opinions,but they are going to have to see it.then use your own judgment.someone out there knows.metal specialist i mean people that have done it for a few years,that type of metal.

 

[dave6666]

It can certainly be done. And yes, warping is a concern when putting heat to any sheet metal.

Where are you taking it? Body shop? Metal fab shop?

 

[sirhc76]

http://forums.viperclub.org/rt-10-gts-discussions/598655-stripping-paint-sidesill.html

post 9

 

[piper1112]

Body shop was the plan

 

[dave6666]

Well just tell them what a replacement one costs and request they put their best man on it. Or better yet, tear a soda can in half and request you watch the guy weld it back together. I'm not joking...

 

[piper1112]

would you suggest a metal fab shop?

 

[piper1112]

Well just tell them what a replacement one costs and request they put their best man on it. Or better yet, tear a soda can in half and request you watch the guy weld it back together. I'm not joking...

What's the replacement cost?

Piper

 

[dave6666]

I would suggest whomever understands the process at hand, and the consequences of failure. Both, if qualified, are good choices.

If they say we can try it... Leave! You get one chance a lot of times unless you also know some sheet metal wizard under the bridge kinda troll dude that can shrink and pound it back into shape after it's been warped.

 

[mjorgensen Woodhouse]

I thought that the holes were cleaned out and filled with aluminum solider the smoothed? Did not think there was any actual welding done. It does need a special primer after though, the body shop should no that.

 

[dave6666]

What's the replacement cost?

Piper

Factory new $5K each. Not joking...

 

[dave6666]

I thought that the holes were cleaned out and filled with aluminum solider the smoothed? Did not think there was any actual welding done. It does need a special primer after though, the body shop should no that.

Solder still takes heat. Maybe even more than TIG with a chill bar. Problem is trying to get a chill bar to fit tightly on a curved sill surface.

 

[piper1112]

QUOTE=dave6666;2709301]Factory new $5K each. Not joking...[/QUOTE]

HOLY S@#T....what's that all about? Are there decent aftermarkets?

Piper

 

[dave6666]

Yes. I have the Autoform fiberglass ones on my car. Which has also been converted to side exhaust ('01 GTS). There are others too, like carbon fiber for a couple G's a pair. The Autoform's are about 1 G. Parts Rack is your go to there.

 

[piper1112]

Thanks for your info....I am assuming these sills are aluminum...correct?

Piper

 

[dave6666]

The factory sills are aluminum. I'm not aware of any aftermarket aluminum ones.

 

[piper1112]

Yes. I have the Autoform fiberglass ones on my car. Which has also been converted to side exhaust ('01 GTS). There are others too, like carbon fiber for a couple G's a pair. The Autoform's are about 1 G. Parts Rack is your go to there.

Did you replace yours do to damage?
Are they a G for the pair?

Piper

 

[dansauto]

Solder still takes heat. Maybe even more than TIG with a chill bar. Problem is trying to get a chill bar to fit tightly on a curved sill surface.

This is an incorrect statement, solder does not take more heat than to tig. I also would like to see someone tig weld an aluminum anodized soda can. The al oxide has a much higher melting point, unless that is removed you will burn thru the can everytime.

To weld these you should use a copper "backing" plate that allows you to "puddle" the filler rod and fill the hole. It also reduces the chance of warping if you insert the filler rod in the tourch plume. (it vaporized the al filler rod and lets it reform as a puddle on the backing plate) The al does not stick to the backing plate so when it drys you have an nice clean weld will minimal grinding. Heat sinks are not necessary unless you are going to run a bead.

 

[dansauto]

If you want to trade yours in mike (99R/T10) has some repaired ones in stock...

 

[dave6666]

This is an incorrect statement, solder does not take more heat than to tig. I also would like to see someone tig weld an aluminum anodized soda can. The al oxide has a much higher melting point, unless that is removed you will burn thru the can everytime.

I hate people that quote me incorrectly.

I did not say one way or another that solder is hotter or TIG is hotter. I said maybe so. That means I do not accurately know, but am speculating, not making claims to precise knowledge thereof. My bottom line there is both processes take heat. One is not a cold process while one is a hot process kind of statement.

Also, who said anything about an anodized soda can? Are they anodized? Anyway, if you want to see it done you'll need a plane ticket to first.

 

[dave6666]

Did you replace yours do to damage?
Are they a G for the pair?

Piper

I replaced mine as I was converting to side exhaust. Some people just hole saw their stock sills for that but I wanted the molded in look of the Autoform side pipe outlet.

And yes, the price is per pair. Give Jon B at Parts Rack a jingle for those details.

 

[dansauto]

I hate people that quote me incorrectly.

I did not say one way or another that solder is hotter or TIG is hotter. I said maybe so. That means I do not accurately know, but am speculating, not making claims to precise knowledge thereof. My bottom line there is both processes take heat. One is not a cold process while one is a hot process kind of statement.

Also, who said anything about an anodized soda can? Are they anodized? Anyway, if you want to see it done you'll need a plane ticket to first.

Of coure they are, how do you think they get the designs and text on them? It is really great that your willing to grace us with your persistent posts, I see you joined in 2007, I can’t remember how it was before you came along, but it is a blessing that what ever life you had before was suspended for our benefit.

 

[piper1112]

Hey Guys,

What about an aluminum epoxy? I took my car into a very high end body shop that does Enzo work ...just to give you an idea, and they suggested an aluminum filler that the gaurantee wont be effected by the heat??? I might post this as a new thread if alot of the responders dont make it back to this thread to see this.

Piper

 

[dave6666]

Of coure they are, how do you think they get the designs and text on them? It is really great that your willing to grace us with your persistent posts, I see you joined in 2007, I can’t remember how it was before you came along, but it is a blessing that what ever life you had before was suspended for our benefit.

I will post here to my liking, as I am actually a paying member.






And if you want to get into a word game contest with me, I am the master. It won't take me 2 posts and your place will be called davesauto.



I will OWN you that quick.



Make me stop...

 

[dave6666]

Hey Guys,

What about an aluminum epoxy? I took my car into a very high end body shop that does Enzo work ...just to give you an idea, and they suggested an aluminum filler that the gaurantee wont be effected by the heat??? I might post this as a new thread if alot of the responders dont make it back to this thread to see this.

Piper

Epoxies have come a long way since I was born (which has been suspended for a while - see above!) and I'm sure they're good, but for the most "proper" fix, metal is it.

It is your car, but do you want what basically amounts to fancy body filler?

What are your price quotes at this point? Metal repair, filler repair, etc.

 

[ACELLR8]

I will post here to my liking, as I am actually a paying member.






And if you want to get into a word game contest with me, I am the master. It won't take me 2 posts and your place will be called davesauto.



I will OWN you that quick.



Make me stop...

Please stop already!! You are an embarrassment to any Marine who has worn the uniform

 

[piper1112]

Epoxies have come a long way since I was born (which has been suspended for a while - see above!) and I'm sure they're good, but for the most "proper" fix, metal is it.

It is your car, but do you want what basically amounts to fancy body filler?

What are your price quotes at this point? Metal repair, filler repair, etc.

The reason for the epoxy is that the area behind the sill ( after investigation) was found to be corroded to the point that it was through half the thickness of the aluminum sill...2 different body shops gauranteed the epoxy as that was the only option short of welding a new piece in after cutting the old one out. They both decided that a weld attempt could cause the area to collapse due to the thinning from corrosion.

Piper

 

[dansauto]

The reason for the epoxy is that the area behind the sill ( after investigation) was found to be corroded to the point that it was through half the thickness of the aluminum sill...2 different body shops gauranteed the epoxy as that was the only option short of welding a new piece in after cutting the old one out. They both decided that a weld attempt could cause the area to collapse due to the thinning from corrosion.

Piper

it probably will work, but they need to clean it good or it wont stick. I have welded a bunch of these and once the corrision is ground down you can always cut a small pc of al and weld it back in. I think they are steerinig you this way because they don't want to mess with trying to weld it. Did you contact any welders? The only thing about epoxy is the adhesion and possible break down over time with the heat from the exhaust.

 

[dansauto]

I will post here to my liking, as I am actually a paying member.






And if you want to get into a word game contest with me, I am the master. It won't take me 2 posts and your place will be called davesauto.



I will OWN you that quick.



Make me stop...

You must have misunderstood me. I certainly do not want you to stop. I can tell by your venom membership that you take this seriously. I concede to your post count is most impressive, especially given the content of your posts.

 

[dave6666]

Please stop already!! You are an embarrassment to any Marine who has worn the uniform

Huh? *** does that have to do with anything?

Not that half the stuff I say is on topic.