I have had a far amount of success welding patch panels on this rust bucket of a panel truck. I started on the floor pan, then the inner/outer cowl, also welded in a piece of rotted out tool cubby under the driver seat riser. So I thought I was ready to weld on the lower patch between the back of door and rear fender. Turned out to be the worst panel yet. I have a couple spots that are convex and another are that is concave, also the area that is concave has kind of warped the area above it giving it a kind of oil can effect. I have tried to tap the high area down but with no way to get a dolly behind it my efforts were futile. This is the method I have been using to weld so far with success until now (using a hobart handler mvp 220v #2 setting): I tack welded every inch or so then smoothed out the tack welds, then skipped around filling in between the tack welds, checking to make sure everything cooled before next weld. Any advice on what I may be doing wrong so I can get it right on the other side. Don't know what I can do about drivers side, thinking about cutting it out and starting over! I have welded this in with a slight gap about 1/32 between panels I have read conflicting views on this on the web some say to butt the two pieces together others say to leave a small gap as the metal will expand. Which way is correct?
Thanks, Paul
