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 Post subject: Re: Project MJ CRD is born:
PostPosted: Wed Oct 05, 2011 7:52 am 
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Sir Sam wrote:
Passenger side bracket welded on(the thin stuff at the top was a witch)
Image



http://www.weldingtipsandtricks.com/ :)

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 Post subject: Re: Project MJ CRD is born:
PostPosted: Wed Oct 05, 2011 10:17 am 
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You use flux core on 20ga? For thin sheet metal you better use .023 solid wire with C25 gas (75%Argon/25%CO2) If your Mig have no gas option you can limit the heat by using a piece of copper in the back of the area you weld. Use .030 flux core wire and set your mig to lower possible setting. Try the tac weld technique you can learn from the excellent link Warp post. Good preparation is the key, grind all the area.

For 20ga I set my Miller 211MM to 2.5/25 and use .030 solid wire with C25 gas, the Millermatic setting is a bit to hot for my taste but It's a good start for a old rookie like me :)

Hope you finish this pretty one very soon :wink:

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 Post subject: Re: Project MJ CRD is born:
PostPosted: Wed Oct 05, 2011 11:00 am 
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OldSkull wrote:
You use flux core on 20ga? For thin sheet metal you better use .023 solid wire with C25 gas (75%Argon/25%CO2) If your Mig have no gas option you can limit the heat by using a piece of copper in the back of the area you weld. Use .030 flux core wire and set your mig to lower possible setting. Try the tac weld technique you can learn from the excellent link Warp post. Good preparation is the key, grind all the area.

For 20ga I set my Miller 211MM to 2.5/25 and use .030 solid wire with C25 gas, the Millermatic setting is a bit to hot for my taste but It's a good start for a old rookie like me :)

Hope you finish this pretty one very soon :wink:


No I used a 1/16" rod on my arc welder at 50 amps(the lowest setting) on 20 gauge.

And the surface was good and clean.

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 Post subject: Re: Project MJ CRD is born:
PostPosted: Wed Oct 05, 2011 11:21 am 
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Thought that looked like stick weld work. Even back in the day when my hands were steadier it was hard for me to get a clean job on thin material with a stick welder. Much easier today with a MIG even with somewhat unsteady hands.

Look forward to pics of the finished product.

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 Post subject: Re: Project MJ CRD is born:
PostPosted: Wed Oct 05, 2011 12:31 pm 
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OldSkull wrote:
If your Mig have no gas option you can limit the heat by using a piece of copper in the back of the area you weld.


I had to Google this one. Good idea!
The copper melts at a higher temperature and the steel won't stick to the copper. Good for fixing blow through holes too.

Use rare earth magnets to hold the copper sheet in place.


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 Post subject: Re: Project MJ CRD is born:
PostPosted: Wed Oct 05, 2011 12:59 pm 
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It's a old trick Squeeto! Help a lot if you weld aluminium :wink:

Sir Sam wrote:
No I used a 1/16" rod on my arc welder at 50 amps(the lowest setting) on 20 gauge.
And the surface was good and clean.

It is too thin to weld with a standard arc electric welder. Long ago I use to do body work thin metal using oxyacetylene before I get a MIG and keep my arc welder for "heavy" stuf. The best of all for thin material is TIG welding not easy to master but the result are amazing.

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/Hayden HY2905 Viscous clutch with OEM 52079654AE fan mod
Samco/OME/Bilstein/JBA4.5/Mattech BTA Machined trans valve body
/BF rugged terrain 245/75/16 on MOAB

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 Post subject: Re: Project MJ CRD is born:
PostPosted: Wed Oct 05, 2011 2:47 pm 
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warp2diesel wrote:
Sir Sam wrote:
Passenger side bracket welded on(the thin stuff at the top was a witch)
Image



http://www.weldingtipsandtricks.com/ :)



Hey Warp is this your P.O.O.P...I mean weld? I wish people stop posting pictures of your best work! Dam internet.. :ROTFL: :ROTFL: :ROTFL:

Just kidding you Sam :mrgreen: I'm so jalous of your project :wink:

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2005 CRD Ltd/Tru-Cool 4454 LPD
/Filter bleeder CRDBV/Fumoto F102/ProVent 200/Euro TC
/Hayden HY2905 Viscous clutch with OEM 52079654AE fan mod
Samco/OME/Bilstein/JBA4.5/Mattech BTA Machined trans valve body
/BF rugged terrain 245/75/16 on MOAB

ImageImage


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 Post subject: Re: Project MJ CRD is born:
PostPosted: Wed Oct 05, 2011 3:35 pm 
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OldSkull wrote:
It's a old trick Squeeto! Help a lot if you weld aluminium :wink:

Sir Sam wrote:
No I used a 1/16" rod on my arc welder at 50 amps(the lowest setting) on 20 gauge.
And the surface was good and clean.

It is too thin to weld with a standard arc electric welder.


No kidding, but I make do with what I have.

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 Post subject: Re: Project MJ CRD is born:
PostPosted: Wed Oct 05, 2011 6:10 pm 
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Sir Sam wrote:
No kidding, but I make do with what I have.

I understand and feel very sorry you have to deal with such issue doing this amazing project but you realy need to find another way, this weld look not secure and you don't want your dash to collaspe on the first bump you hit on or off the road.

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/Filter bleeder CRDBV/Fumoto F102/ProVent 200/Euro TC
/Hayden HY2905 Viscous clutch with OEM 52079654AE fan mod
Samco/OME/Bilstein/JBA4.5/Mattech BTA Machined trans valve body
/BF rugged terrain 245/75/16 on MOAB

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 Post subject: Re: Project MJ CRD is born:
PostPosted: Wed Oct 05, 2011 7:38 pm 
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OldSkull wrote:
Sir Sam wrote:
No kidding, but I make do with what I have.

I understand and feel very sorry you have to deal with such issue doing this amazing project but you realy need to find another way, this weld look not secure and you don't want your dash to collaspe on the first bump you hit on or off the road.


I went back in yesterday and finished welded the bracket in, I went through and slowly got the rest of of that welded in place.

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 Post subject: Re: Project MJ CRD is born:
PostPosted: Wed Oct 05, 2011 11:59 pm 
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Sir Sam wrote:
I went back in yesterday and finished welded the bracket in, I went through and slowly got the rest of of that welded in place.

Happy you find a way to did it with what you got on hands without punching a hole! :mrgreen:

They just need to past the hammer test not winning a beauty contests since it's under the dash...

Now we all standing on the tips of our chair so GET-ER-DONE for cr...sake! :furious: :POPCORN:

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2005 CRD Ltd/Tru-Cool 4454 LPD
/Filter bleeder CRDBV/Fumoto F102/ProVent 200/Euro TC
/Hayden HY2905 Viscous clutch with OEM 52079654AE fan mod
Samco/OME/Bilstein/JBA4.5/Mattech BTA Machined trans valve body
/BF rugged terrain 245/75/16 on MOAB

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 Post subject: Re: Project MJ CRD is born:
PostPosted: Thu Oct 06, 2011 2:15 am 
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OldSkull wrote:
Sir Sam wrote:
I went back in yesterday and finished welded the bracket in, I went through and slowly got the rest of of that welded in place.

Happy you find a way to did it with what you got on hands without punching a hole! :mrgreen:

They just need to past the hammer test not winning a beauty contests since it's under the dash...

Now we all standing on the tips of our chair so GET-ER-DONE for cr...sake! :furious: :POPCORN:


Very very short tacks, arc welder is just the wrong wrong thing for this, but I made it work. It ain't pretty, but its welded in place,

Hammer test succesful, nothing pretty, but it holds.

lots more work to do, but ill git er done.

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 Post subject: Re: Project MJ CRD is born:
PostPosted: Thu Oct 06, 2011 8:49 pm 
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Got some spare time so I mod one of the pic of the 2500 with paint....Feel free to use photoshop to give a feet or two to the bed and add a lift kit ! :mrgreen:

Image

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2005 CRD Ltd/Tru-Cool 4454 LPD
/Filter bleeder CRDBV/Fumoto F102/ProVent 200/Euro TC
/Hayden HY2905 Viscous clutch with OEM 52079654AE fan mod
Samco/OME/Bilstein/JBA4.5/Mattech BTA Machined trans valve body
/BF rugged terrain 245/75/16 on MOAB

ImageImage


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 Post subject: Re: Project MJ CRD is born:
PostPosted: Fri Oct 07, 2011 12:19 am 
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OldSkull wrote:
Got some spare time so I mod one of the pic of the 2500 with paint....Feel free to use photoshop to give a feet or two to the bed and add a lift kit ! :mrgreen:

Image


Image

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 Post subject: Re: Project MJ CRD is born:
PostPosted: Fri Oct 07, 2011 5:59 am 
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Holy Moly! What a beauty! Look nice lifted with MOAB and Goodyear MT/R but yours his even better...It's a half ton "diesel" pickup! Something we ask for and no car maker provide on this side of the world to date. Good chance we seen your truck in magazines as soon you finish it! :)

PS:Write to Stacey David (GearZ show at Speed channel) and talk about your project. You can win a Miller product so don't forget to tell him you need a MIG pronto! :-)r

http://staceydavid.com/

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2005 CRD Ltd/Tru-Cool 4454 LPD
/Filter bleeder CRDBV/Fumoto F102/ProVent 200/Euro TC
/Hayden HY2905 Viscous clutch with OEM 52079654AE fan mod
Samco/OME/Bilstein/JBA4.5/Mattech BTA Machined trans valve body
/BF rugged terrain 245/75/16 on MOAB

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 Post subject: Re: Project MJ CRD is born:
PostPosted: Sat Oct 22, 2011 11:36 pm 
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Sir Sam wrote:
OldSkull wrote:
Got some spare time so I mod one of the pic of the 2500 with paint....Feel free to use photoshop to give a feet or two to the bed and add a lift kit ! :mrgreen:

Image


Image


That looks awesome!

Really makes me think about putting a 2.8 in my WJ!! :JEEPIN:

Think i'll be calling Keith at GDE on Monday


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 Post subject: Re: Project MJ CRD is born:
PostPosted: Fri Dec 30, 2011 9:14 pm 
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I love watching this thread!

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 Post subject: Project MJ CRD is born:
PostPosted: Fri Dec 30, 2011 11:03 pm 
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I just read the entire thread. My head hurts. You need to start production. I want one

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 Post subject: Re: Project MJ CRD is born:
PostPosted: Fri Jan 06, 2012 8:10 pm 
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Updates online at:

http://colorado4wheel.com/forum/viewtop ... 6&p=36#p36

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 Post subject: Re: Project MJ CRD is born:
PostPosted: Sat Jan 07, 2012 7:27 pm 
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More updates:

http://colorado4wheel.com/forum/viewtop ... 6&p=40#p40

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