B pillar junction help

Whoo-Hooo, the photo links worked!

Ooops - this is the left (drivers) side.

That corner is a complex part of the car where several parts are joined together. You may find some idea of what the inner structure looks like here inner b-pillar
but that doesn't show the outer B-post and quarter panel skins. If there is rust, then I would slowly take the corner apart part by part.

Rodney,

I had exactly the same rust on my car. I cut it off and made a new piece out of 3 or 4 different sections and then spot welded (actually plug welded with MIG) back together. It's not as hard as it looks. I didn't take as many pictures in those days so cant show you how I did it.

Johnny

Kristian, thanks for the link to your work. I read your Euro GTS restoration thread a few months ago. I see you have added more. There are many of your photos that are very helpful. As you say, I will just cut it apart a little at a time, stop when I get to good metal. Take lots of pictures and save the rusty bits to help me make the replacements.

Johnny, that is what I have in mind. I have been using plug welds with my MIG on other parts I have done so far, but some times not so good results. I do not get good penetration in the base metal. The arc jumps to the edge of the plug hole too soon, before the base metal has melted. Here is an example ...



Maybe I need to use a bigger hole to start with - what size hole do you use?

Rodney,

You need to turn the power way up for plug welds. Make sure there is no gap between the pieces you are joining. Practise on some scrap bits. I use 6mm hole for 20 gauge and 7mm for 18 gauge.

Johnny