Smart Question for Smart People - Welding Dash

[amcordo]

Hi!

I removed the two dash segments from my S3 bulkhead and I'm really struggling with what to do to mount dials, etc. I guess one of the options is fix up the old dash segments and reinstall them. The lower dash has serious rust holes in it. Can metal that thin be welded? If so, can anyone suggest a cheap beginners welder of the appropriate type for me to purchase?

[albersj51]

My old International Scout had a similar situation on the top and when we used a flux core welder (cheap beginner welder) it ended up Melting the metal on the top and not fixing it. You're probably better off cutting off to good, solid
metal and welding in new stuff from there. Just my .02.

[solihull109]

You need to T.I.G. weld material that thin, however this is not for the beginner. It is very easy to completely destroy the project if you are not a seasoned welder.

[leafsprung]

Cheap welders arent too good with thin materials. a new dash is probably cheaper. I have a lower one that is rust free but has some drill and radio holes . . .LHD trade me something and its yours.

[printjunky]

Tony, not that you want to wait to see where it falls on my list of winter projects, but I'm planning on using my old super-rusty, but mostly structurally sound lower dash as a plug to make a mold to try making a fiberglass lower dash. I'll document here or somewhere similar and link here at the RN forums.

[amcordo]

Tony, not that you want to wait to see where it falls on my list of winter projects, but I'm planning on using my old super-rusty, but mostly structurally sound lower dash as a plug to make a mold to try making a fiberglass lower dash. I'll document here or somewhere similar and link here at the RN forums.

YES YES YES! I can wait. Supposedly Lasalle has a fiberglass dashboard, but I don't know anything about it. Just emailed them yesterday and haven't gotten a response yet. http://www.lasalle-trim.co.uk/products

[Terrys]

I'm planning on using my old super-rusty, but mostly structurally sound lower dash as a plug to make a mold to try making a fiberglass lower dash.

Very good idea. I suspect you could sell a few.

[CharlesF]

When I weld holes and pin holes in thin sheet metal I back up the weld area with copper sheet. The copper sheet acts as a heat sink.

If the damage is severe I use Silicon Bronze rod, it melts at lower temps, similar to brazing.

The copper sheet works well with both Tig or Mig process, prefer Tig because of the exact heat control.

Hope this helps!

Charles

[amcordo]

OK, so I got a response from Lasalle and they do make dashboards. But only for RHD rovers. Ugh. And they sent me a couple of pictures - they're really snazzy looking. So back to square one. I've been offered a lower dash piece in good condition for trade. Has anyone ever galvanized a dash before? I did all of those pieces earlier this summer and they survived just fine. Only they weren't of such thin metal, nor were did they have the angles invloved - lots of room for stress warpage.

[amcordo]

OK, new plan

OK, so I'm just going to clean cut the rusted areas with a grinder, attempt to galvanize it, and then when I reassemble it (if it survives the zinc bath) I'll just cheap-lazy man weld on a new, galvanized sheet over the cut out areas (and when I say "weld" I mean use solder or something). If I do it right it'll look OK, and be just as useful as new! I may end up having to cover it with the vinyl cover or a thick bed liner coat to make the new plate look less noticeable but that's acceptable. Cross your fingers for me - pray for no warping!

http://www.flickr.com/photos/39748444@N03/5018713144

[SafeAirOne]

Well that doesn't look nearly as bad as it sounded. I'd try and keep it simple, since this piece in invisible anyway (or it will be after you re-cover it), I'd either bend up a new corner and rivet it over the bad area or I'd bend up a new corner flush patch if I were being really particular.

When I got done, I'd find an appropriate adhesive (that plenum can get pretty hot with the heater on) and cover it with as thin a piece of black naugahide as I could find.

It'll look pretty original and nobody'd ever know... Why complicate things with welders, galvanizing and the like, especially when it's a flat piece with one or 2 straight-line bends?

[amcordo]

All great advice! Thank you!

I'm still going to try and galvanize it so that I don't ever have to think about it rusting. But after that I'll give your flush rivet fix a try. Note that i will drill the rivet holes before galvanizing.

[SafeAirOne]

In that case, why not patch it so it looks good, then have it powder coated black? You kill 2 birds with one stone that way.

[thixon]

Tony,

either ship it down, or drive it down one weekend and I'll patch it up for you. If you come down, I'll teach you to TIG weld. You can pay me in beer.

[LaneRover]

Tony,

either ship it down, or drive it down one weekend and I'll patch it up for you. If you come down, I'll teach you to TIG weld. You can pay me in beer.

I may take you up on that the next time I have a job in Atlanta.