Welding Work

After the initial cutting, I had to get down to some serious business. I had cut away part of one of the roof support pillars and this had to be made good. We were taking away one such pillar and putting back two, so I was satisfied that, when I finished, the shell would be at least as strong as it was when it originally left Wolfsburg. I also had to make good the damage done by the dreaded tin-worm aided and abetted by VW’s misguided use of the equally dreaded foam filler.

I had the advantage of a very nice piece of equipment for making spot welds. It weighed half a ton and I wouldn’t want to use it for very long! But it was magic for patching where I could get at both sides. But there was still quite a bit of work that had to be done with a mig welder.

But before I could install the door frame, I had to attend to some rot around the rear wheel arch.
A close-up of the spotwelder in action. It is simplicity itself. First, line the jaws up on the desired spot ;-)
Then squeeze the handles to start the weld. Hold until the metal glows bright with the heat (experience teaches you how much) then squeeze tighter which cuts off the current and holds the job together until it sets.
If you haven’t cleaned off the old paint or filler properly, you get to start a small fire as here! The dreaded foam can also generate a lot of noxious smoke when you get close to the back of the sill.