Welding auto sheet metal

hostile

hostile

Well-known member
In the process of rebuilding a Ford F250. I've had to pull the windshield out due to leaks and have found that there are areas rusted through at the top of the windshield header. So I either have to lead it in, replace the header with a donor or try to weld it up. I have a TIG/stick welder and a set of torches but no MIG capability. Looking for advice on what might be the best way to fix this? If MIG is the way to go does anybody have any tips on setups. Thanks. :florida: :rebel:
 
Tig is doable, mig is quicker for tacking it up but you have to dance around with the tack welds as not to distort the panel, then you have to grind all the excess away making sure the whole seam is complete as to not get ghost lines in the finished paint job. I'd stick with tig.
Finding donor vehicles like I have been trying for my 77 is not very easy these days. You may need a shrinker/stretcher and a bead roller depending on the area you need to replace. Do yourself a favor and try protecting everything from the back side once you open things up to prevent further rust issues. They sell a weld thru primer for this kind of work.
 
be careful of electral wiring that may be hidden where you need to repair. if the damage is not too extensive you may want to consider cleaning up the rust and filling with some of the new epoxies. good luck
 
Guys, thanks for all the advice. Theres quite a bit of material missing on the upper windshield header so I'm sort of hesitant on using fillers. It is a beater so maybe it's something to consider. If I go the welding route I may get lucky in that since it's a 2001 model it appears that replacement headers are still available from Ford. Was heading for the dealership today to check it out when I got sent out on an emergency call. Maybe tomorrow. :florida: :rebel:
 
Shoot, 2001? Use all metal after wire wheeling and roughing with a grinder, it'll be there forever. I was thinking of a pre '80 truck.
 
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