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  #1  
Old January 7th, 2014, 03:17 PM
CaptMidnite
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Daniel Choi
94 NAS Defender 90 ST
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footwell replacement

Ok, I know this topic has been covered a million times. I've searched here, You tubed and even looked at Jeep forums. But basically everyone says, "Just weld in new metal, ta da!" and skips from Step A (cut out hole) to Step B (replacement panel in place for welding)

I'm probably going to outsource the welding. My question: When I trim away the old metal, do I cut the hole slightly smaller so the new piece can overlap on top of it? Also, it seems the footwell metal has to be flanged to accept the new piece. (see pic) Then, the whole thing is spot welded. Is my understanding of the process correct? I've never welded but I thought I'd do the preliminary trimming and save some labor costs.
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  #2  
Old January 7th, 2014, 03:31 PM
CaptMidnite
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Daniel Choi
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Or as an alternative, can the replacement panel be "butt welded?" This case seems to require a matching fit.
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  #3  
Old January 7th, 2014, 04:00 PM
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Bill Adams
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The patch is cut to fit the hole with maybe 1 16th or 32nd inch gap. You hold it in place with magnets flush with the foot well. Tack weld the part in place in at least 4 places. Finish welding by making a gazillion tack welds all around the perimeter until the joint is filled in. Best not to work in one area, but work all around in different areas to prevent heat warping. Keep wire wheel handy to keep weld area clean. Grind, sand, finish.
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  #4  
Old January 7th, 2014, 04:12 PM
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Bill Adams
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He said butt.
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1966 109 5 door wagon 300Tdi "spermaceti fueled"
1994 RRC LeWiB "ruining the air behind me"
1968 2A 88

All my troubles are Rover
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  #5  
Old January 7th, 2014, 04:29 PM
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Chris
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Butt weld defined: Go outside to metal flagpole drop pants stick butt on pole for thirty seconds. Repeat if necessary.
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  #6  
Old January 8th, 2014, 09:27 AM
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Don Lang
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If you are going to outsource the welding the person you should be asking this question to is the welder.
They will tell you how they want or prefer it being prepped.
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