Thread: Welding VW fenders to body questions

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if from rust if the flange were the fender bolts up is gone you use 3/4 tape to make a clean cut line trim only as much needed the clean it up . then drill some 1/8 self tap screws to adjust fenders for the best fit up were you use the 1/8 screws i punch a 5/16 hole in fender with fender washers or just bigger washer on the 1/8 screws so you can move fender abit if needed get them fitted good leave screws in for now all stuff needs to be very clean how you go about this is up to you . use a good weld thru primer you will have a over lap in a bad spot so it need to be sealed up very good . now on the out side of fender to body fit up needs to be very good less weld less grining better luck with no warping the outside weld you want small and clean neat so your not grinding the weld off and making metal thinner were you want it to hold as in time it can crack out .when all done you do want some weld on the fender and in time crack so EZ on the grinder so a ligth hand and blend... when the outer is all welded up go back take screws out and plug weld holes up this will help hold fender up as to how many plug holes i would go about 5 inchs a plug hole around the fender. tack the under side edge were you would cut fange off fender. yep alot of welding then you will have to seal this up when welding is done you will want to use a sealer . i brush west system in joints can use a thickener in the west system like ground glass. so first thing is every thing needs to be clean metal were your welding the hammer and doly fit up may be needed if you can bolt them up and no rust you could try to metal bond them on ? clean every thing bolt fender were it fits the best drill some 1/8 line up hole leave all bolts in that you can to get fender to drop for a air gap lay bead of metal bonder on then draw up with bolts not to much you would not want all the bonder to squeeze out. you would want to work fast. or bolt fender up and weld the fender on if you have rust free body parts .welding any body metal you want to move around alot to keep heat down i never weld more then 3/4 at a time if you use a mig you may have a hump up on the welds when starting to fill in your 3/4 welds i grind the ends of the welds down to cut down on weld build up and cold welds and less heat .i used a stone on a angle grind clean welds as i go and not after all welded up .on sanding disc as i feel you have less heat with a good stone wheel keeping warping down. for fillers first coat on welded or weak metal i all ways marglass or a good grade of ground glass filler