Hi guys I'm at the point gonna scrap my zx, really pi@#ing me off.

I have a problem in the engine bay and can't finish my respray to its done.

 

This is the problem

 

 

I had some rust I cut it out and welded in a patch, but it keeps coming out crap.

So now cut it out again and hole is getting bigger and bigger.

 

I want it right and just can't do it.

 

I even cut the part from a spare zx I have welded it in a was going good then tried grinding welds down and either side of welds keep getting thin.

And now that's ruined.

 

Anyone know a welder in Kent area that could fix this, I have the welder and tools.

 

Can't move the car to take it anywhere either I'm really in the crap and don't know what to do.

 

This is what it looked like when I done it

 

 

I painted it black and used some seam sealer on it all over the welds to stop it rusting till my next day of today and then when trying to grind welds flush metal around welds got thin and cut the whole lot out again.

If you get stuck, I know an outstanding welder, if he can't do - it basically can't be done! He is mobile as well, so can come to you. Pm me if you need his details.

what welder are you using and what shielding gas is it...look to me like you dont have enough amps and the wire feed is too fast mate...it just needs small hot fast spot welds on silver steel and then you wont get the weld build up you seem to be having.For grinding back you then need a flap wheel instead of a disc as they are to aggresive i think...BTW i use couger light gas from air products much much better than CO2 that pubs use..No its far from ruined mate..LOL

 

Exactly Bri,a flap disc is far better to dress welds,grinders are harsh and remove to much material,linish the welds flat and it should be fine,pulse the welds in if you cant do a flat out seam,and pull dont push,car welding is the only time you should pull the welder to avoid heat build up.

Cheers for your reply,

 

Gonna drive to mark derby today and get the new part,thank u mark...

Then I'll let someone else do it lol.

 

The welding wasn't really the problem, its more the cleaning it up I'm struggling with keep making either side of the welds turn blue and then it cracks cause its to thin.

I did use a 40grit flap disc,

 

Then again it's proberly my welding and grinding, I'll let someone else fix it otherwise ill end up cutting the car up, I do go a little nuts with a grinder.

Well guys,

 

I drove to derby yesterday, and cut the part I needed out.

Thank u mark derby, great guy.

 

Got up this morning and thought sod it I'm gonna do this that stupid zed ain't winning.

 

This is how far I got do u guys think it will be ok, no laughing at me please...

 

I decided I was gonna do the butt welds where the stock seam sealer is, so I can grind the welds just a bit and make it look like seam sealer and the seam sealer is where the rust started so hopefully it will solve that too.

 

May even clear of the seam sealer in the rest of the bay and weld it up any opinions on that, good or bad idea lol..

 

Well here's some pics

 

 

 

 

 

 

 

 

 

Again please be nice lol, any advice or tips if this will be strong enough and ok would be great..

 

Thank u.

Have you got penetration thru to the underside??

If so it will be Ok although some very light trimming with a flap wheel is needed as some of your weld is still a bit proud. Then smooth over with seam sealer.

Yeah it's gone right through and gonna use flap disc on welds tomorrow ain't touched them yet.

But gonna clean them only a little bit so welds look like Seam sealer once it's all painted.

just get them http://www.zcentre.co.uk/index.php?page=shop.product_details&flypage=flypage.pbv.tpl&product_id=60&category_id=14&option=com_virtuemart&Itemid=7 stick on top and nobody gonna see the welds :)

as i weld 4 a living but never on a car, usually the best way is to turn your juice down low put a sealing run along, let it cool, then grind nearly flush and grind a slight groove where you want the run to lay, use anti spatter and turn juice up slightly 2get a better looking weld then you shouldnt get any overlap or undercut and also should'nt blow thru

as i weld 4 a living but never on a car, usually the best way is to turn your juice down low put a sealing run along, let it cool, then grind nearly flush and grind a slight groove where you want the run to lay, use anti spatter and turn juice up slightly 2get a better looking weld then you shouldnt get any overlap or undercut and also should'nt blow thru

 

I just been sort of stitch welding it, please don't tell me to grind it flush lol, I'm useless with the grinder I'm to heavy handed and keep going to far with it making the metal thin.

Hopefully what I'm doing now welds will look like seam sealer if not I'll get them covers lol.

Thanks for your reply.

 

just get them http://www.zcentre.co.uk/index.php?page=shop.product_details&flypage=flypage.pbv.tpl&product_id=60&category_id=14&option=com_virtuemart&Itemid=7 stick on top and nobody gonna see the welds :)

 

Them inner wing things are cool, I'll look into them if this don't come out right,

Thanks for that.

I just been sort of stitch welding it, please don't tell me to grind it flush lol, I'm useless with the grinder I'm to heavy handed and keep going to far with it making the metal thin.

Hopefully what I'm doing now welds will look like seam sealer if not I'll get them covers lol.

Thanks for your reply.

 

Them inner wing things are cool, I'll look into them if this don't come out right,

Thanks for that.

 

the trick with a grinder is to break the disc in and take its corner away then u cant cut in2 the steel easily and then just let the grinder do the work 4u, absolute doddle once u know how!

the trick with a grinder is to break the disc in and take its corner away then u cant cut in2 the steel easily and then just let the grinder do the work 4u, absolute doddle once u know how!

 

Yeah but I'm useless lol, I just can't seem to get it, end up messing it all up. Looks easy when u watch someone else I do it and go mental.

that now looks a great job Terry...take your time dressing it back now and its cracked mate..Weldone thats better than i could of done:thumbup1:

that now looks a great job Terry...take your time dressing it back now and its cracked mate..Weldone thats better than i could of done:thumbup1:

 

Yeah yeah yeah :blushing: now that's being to nice lol.

 

I am happier with it just a quick, hit with flap disc and that's all its getting lol.

Yeah yeah yeah :blushing: now that's being to nice lol.

 

I am happier with it just a quick, hit with flap disc and that's all its getting lol.

 

no ime serious dude...remember you aint going to get it "factory flat" without losing its strength so dont go to far with the disc:smash:

As znut said it looks ok just easy with the grinder. lol

 

Paul

Cheers guys I'll finish it tomorrow, take it easy with the grinder and put up some pics,

Wish me luck lol.

As znut said it looks ok just easy with the grinder. lol

 

Paul

 

Got your pm; thank u for offering to do it, but had go myself.

Much appreciated mate

Looking good and glad to hear its finally in. I know its already been said but I wouldn't go ott trying to get it looking totally factory cos I think thats where things are going wrong, just tidy it up and seal it and jobsagoodun!

Yep I'll post some pics up of it done tomorrow,

Least I'll be able to finish stone chip and get it back on its wheels, can't wait..

Glad you got there in the end mate. Nice work :thumbup1:

Aarrggghhhh look I can't finish it or can I lol,

 

Working in snow frreeezzzziiiiinnnnnnggggggg....

 

 

It's not deep but it's still cold snow, and it's just my luck my minds been ticking all night thinking how I'm gonna finish the car to wake up to this lol.

wow .. not one bit of snow here

Lots of cups of hot tea will be in order whilst working!

 

It's thawing out a bit now but here's my snowy Z

 

Had today off work and done a bit more to my welds in the engine bay.

It's not finished yet run out of time today so painted it in some primer.

 

Gonna get it all smooth then use seam sealer and make the lines to match the passanger side

 

Gonna wire brush the seam sealer off the passenger so that will have new seam sealer cause its gone a bit hard and that's where the rust seemed to start on the side I repaired.

Hopefully cause I'm gonna put new seam sealer both sides I will be able to make both sides look the same instead of trying to replicate one side...

 

And I got a few runs in the primer, that's what the lumpy bits are in some places,

I think it's starting to look much better now.

 

Got all the paint and stuff soon has I get all the prep work done were gonna paint the engine bay in my garage,

Then I can put pipes, looms and engine etc back in, then drive it to where it's being painted.

 

Think I'll get away with engine bay without oven,

 

So much to do and with work no time to do it.