Start of the project- needs some body work... thoughts and questions for yall

[TexasZ]

OK this is what I am starting with... I need to fix the mini tubs, rear valence, package trey, trunk floor, deck filler panel, and front windshield lip at the top.
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Now for the questions...

-What thickness sheet metal are yall using for patchwork? I am goin to fix the mini tub patches they put on the floor of the car to fill the crappy hole they cut

-As you can see in the photo the firewall has been smoothed, it still has the factory firewall behind it, so my question is how do I make the holes for the accessories since I didnt do it? Is there a template I can lay on it and cut with a plasma cutter? Drill with a hole saw bit?

-What are yalls thoughts on the windshield area. I was told cutting the bottom lip thats got the holes in it off then slipping an L shape up behind the more vertical piece then welding it would be my best bet... any other ideas or is this a bad idea for any reason?

-The rear quaters look like they were patched at one time, and there are some creases, maybe body filler/bondo up near the pillar. If its not bad would you suggest redoing the filler and smoothing it out or replace the whole quarter?

I will probably have some of the major work done at a body shop as I dont have all the tools and space I need, the pics are from my parents house as Im military for now and dont have a place of my own as yet. If you guys have any suggestions, tips, tricks, whatever, feel free to speak up, Im all ears!

[gearheads78]

19ga is best but hard to find. 20ga will work in a pinch.

[TexasZ]

I shouldnt have to much trouble finding 19gauge as my dad works for a fabrication company in San Antonio and has contacts all around for just about anything I could want thankfully.

Another question, using a mig welder, which Ive only done a few times when I was younger, what wire do yall recommend and what settings? What welders are yall using? My dad still knows quite a bit about welding but mostly in industrial, he has welded body panels once but he is more familiar with much thicker metal than this and I could experiment but I figured Id ask yall as a starting point...

[NYC]

Now this is a great project! Good luck with everything.

[TexasZ]

Now this is a great project! Good luck with everything.

Thank you! I just need to get out of the Army and find a decent job in order to pay for everything... lol.:smoke:

[dhutton]

.023 wire works well for sheet metal. Most welders have a label inside the door with recommended settings to start with.

[gearheads78]

The best advise I can give it to practice a bunch with the same metal you are going to work with on the car. Your welder should give a good guide to get started but you will have to fine tune it. Learning to weld and set up your machine on the project itself will do nothing but make a mess and more work for yourself.

[TexasZ]

.023, ok should be easy enough to find. I agree on the practice, I plan on buying more than enough sheet metal to do what I want and be able to practice ALOT. I have a fair amount of practice with stick and flux but not much on mig, good to know theres a guide on most machines, at least new ones. I welded up some rockers on a truck my buddy was working on with flux, even though I told him he needed a mig welder to do it right. Didnt turn out very pretty but after grinding and body filler he said it was perfect... I didnt like it at all, pinholes in the spot welds that I tried to minimize but it was to hot, but it worked for him. Definitely not the type of shortcut I will take on my car...

[NYC]

Thank you! I just need to get out of the Army and find a decent job in order to pay for everything... lol.:smoke:

Thanks for your service to our country. I am sure a project like that will motivate you!

[JRouche]

Ok, Ill step out on a limb (prolly fall off, no biggy).

I bought a 62 nova back in 1995, didnt have any welding time behind me. Didnt even have a welder. I bought a 220vac Mig welder from home depot with the gas kit (it was around $550, a Lincoln). Went to the local welding supplier and bought a gas bottle and some gas with it, 25/75. (25% CO2, 75% Argon). I still have the same bottle and still use the same mix, several refills have been used. I use .23" wire cuase I like it. Its pretty small. But I like that. Its like welding with a needle, I can put the puddle where I want it and control the heat better than with a large wire. Works great for body panels. And I can still weld some heavy 1/4" steel and even some 1/2" plate that has a nice bevel. The .23" wire cranked all the way up digs and WILL weld 1/2" plate if its prepped properly, deep bevels.

Now back to what you are asking. The sheetmetal.

I didnt (and still dont) have a clue. I was just welding and changing things. So I bought five sheets (4x8) of 16ga steel. Had it delivered. I bought 16ga cause I knew I had to remove my floor, all of it to make room for the 4-link suspension that was coming.

The 16ga is great for the floors, but man!! I had alot left over.

So over the years I started working on the body. It is prolly 20ga steel, Im not sure, I never measured it. But its was thinner than ALL of the extra 16ga sheetmetal I had on hand.

Not a problem, if you arent doing a reproduction car or are building a race car and weight is an issue. I was (still am) just modifying MY street car so I could drive it on the streets.

I shaved my door handles and mirrors and locks and some other work. The heavy 16ga sheet is what I used. It was great to weld to, mending it to the thinner 62 body. I could start a hot weld on the 16ga steel, melt the thinner original sheet into it and not worry about blowing out the weld joint. I still kept to the proper use of heat to minimize distortion. But it was nice to be able to have the thicker metal there as a heat soak to keep the joint from vaporizing away.

I always use butt joints, tight fitting, flush on the top surface. With a butt joint it helps to have a thicker piece of metal in there to start the weld and carry the bead. Is it correct? No, prolly not. I used the 16ga sheet because I had it on hand.

Looking back now, with a lil more knowledge would I change it and use 22ga steel? No. I would not. I still think the 16ga for the floor pan is correct. The patch pieces for the body? Nah, I wouldnt change that. Its nice to have a heavier sheet to weld onto. I wouldnt change a thing. 16ga IS heavy. My entire floor is 16ga, my fire wall is 16ga and my fuel cell (aluminum) tank cover is 16ga. Im happy with it, its great for the floor panels, not gonna be any rocks hurting anything. A lil over board? Yes, prolly so. JR

[TexasZ]

NYC- thanks, yea I def am getting the motivation, I just need to find an artist to render up the car since thats all I can do while Im deployed really lol.

JRouche- so good info on the welder and sheetmetal you used. I appreciate the tips and advice on your experience!