# 209, battery box area mostly done

Rupunzell

Bernice Loui
Rust etched out, sealed, zinc phosphate primer applied, seam sealer applied. Cut out sheet metal areas due to rust damage will be replaced with stainless steel sheet fab'ed as needed, then riveted in place... which results in another primer, seam sealer, clean up cycle before paint.

# 209, front end zinc phosphate primer.JPG


The battery box area.
# 209, battery box, zinc phos primed.JPG



RH headlight area, primer, seam sealer, replacement sheet metal to be made of stainless steel then riveted in place.
# 209, battery box, seam sealer.JPG



Bernice
 
Are You avoiding welding because of possible new rust spreading out of unvisible spots where heat has burned paint off?
 
Welding IS the most difficult method of creating a joint. This is due to heating and cooling of the metals involved. Under "shop" conditions for welding, it is extremely difficult to control the rates of heating-cooling of the metals involved. This results in varied hardness within the welded joint. There are often microscopic cracks and stress risers as a result of welding. These cracks and stress risers can easily propagate when loaded, specially when load cycles up and down and load reversals (car bodies flex LOTs). Add to this, potential contamination of the metal surfaces involved for the welding process.

~All that and more are why so many "shop" made welds fail. It's not "hot glue" folks.. Extremely common at LeMons for a team to weld up a failed structural part only to have that same part fail in a FAR more catastrophic way... beginning at where it was welded up.

To make a proper structural weld means absolute control over the welding cycle and welding conditions and post welding heat treatment of annealing, then heat treating the entire part to produce a uniform material hardness within the entire part. Before all that is done, the welded joint should be inspected for cracks via X-ray or similar.

These problem are one of the many reasons why sheet metal aircraft airframes are not welded, but riveted... which is the preferred method of joining sheet metal except it is labor-skill-speciality materials- cost intensive.

Better alternatives are brazing or hard silver solder where possible.


Bernice


Are You avoiding welding because of possible new rust spreading out of unvisible spots where heat has burned paint off?
 
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