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Video slideshow that outlines how to repair sheet metal. This demonstration was done on a lawn tractor mower deck, but the same principles can be applied to auto body work on vehicles. Most automotive body panels do use a thinner gauge steel, so when welding, more care will have to be taken to reduce the amount of heat distortion. In the video I did use a flux core mig welder, but an argon unit can be used as well.

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Tools/Supplies Needed:
-angle grinder
-angle grinder cutting disks
-angle grinder flap wheels
-locking pliers
-mig welder
-welding shield
-welding gloves
-hammer
-paint marker
-wire brush
-220 grit sandpaper
-paint
-paint brush
-safety glasses
-replacement metal
-propane torch
-adjustable wrench
-clean cloth
-degreaser

Procedure:
-determine to what extent the metal is damaged
-remove the rusty soft/thin areas will allow for a solid area to weld the patch to and also reduces the chance of having the welder burn through the existing steel
-cut out the damaged area using a grinder equipped with cutting disks
-start by forming the new metal to replace the damaged area
-sometimes it is easier to form the replacement metal first before cutting out the damaged area, but the damaged area should still be in reasonable condition to copy the shape or contours
-to form the replacement pieces I used a couple concrete blocks, along with some wood for forming, along with the assistance of a hammer, adjustable wrench, and propane torch
-forming metal will vary depending on what you are trying to achieve
-for my repair I first bent the metal patches, then made relief cuts using the angle grinder with cutting disks so I could form multiple contours
-once finished forming the patches, ensure they fit and remove excessive material from the original panel if needed (it’s better to have more newer metal in a patch repair)
-use the flap wheel for the angle grinder to remove any existing rust or paint to prepare for welding
-fit the patch into place, use locking pliers to hold it into place
-ground the mig welder onto the piece, select a proper heat range
-first tack the replacement piece into place, applying a tack weld every one to two inches
-adjust piece when needed using a hammer, ensuring the edge lines up correctly
-once the piece is held in, then continue with short welds about one inch in length in various areas
-do no run one continuous weld as this will cause warpage
-allow the metal to cool if need
-once the welding has finished, use the flap wheel on the angle grinder to smoothen out the welds
-finally to finish up, for my repair I used a wire brush to clean the mower deck removing any loose rust and paint
-finish up with 220 grit sandpaper to smoothen out the surface
-I wiped down the mower deck with a clean cloth and degreaser
-then applied a farm equipment paint using a brush to the whole mower deck

The cuts in the one rounded patch allows for the piece to be bent into two different directions to match the contour of the mower deck.
Grind the paint off around the area where the patch will be welded to. This will ensure that welder is able to arc on the existing surface properly.

The tack welds hold the piece in place and allow me to align the patch to the existing surface. For the welding, I used a small flux core mig welder.

Running small/short (approx. 1″ length) welding beads reduces the amount of distortion within the sheet metal which is caused by excessive heat. This will have to be adjusted accordingly depending on the gauge/thickness of steel.

For grinding down the welds I used the angle grinder with standard grinding disc for the higher areas and a flap disc to smoothen the surface.

For paint, I used low gloss black farm equipment painted which I brushed on.

Credit:
Music:
Zap Beat – Kevin MacLeod (http://incompetech.com/) Licensed under Creative Commons “Attribution 3.0″ http://creativecommons.org/licenses/by/3.0/

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© 4DIYers 2013
All Rights Reserved
No part of this video or any of its contents may be reproduced, copied, modified or adapted, without the prior written consent of the author.

Living in The Phoenix Metro Area? 5 Key steps to plaster your pool. Visit us: http://arizona.poolsresurfacing.com. Tel. 602-497-0490.

Replastering a swimming pool here in the Grand Canyon state is certainly not a five-minute job. This doesn’t mean that you have to spend money on hiring a professional to do the job. If you are willing to put some time and effort into the project, it is certainly possible to do it yourself. The average swimming pool will require replastering every 7 to 12 years, depending on the method of installation, and how it has been maintained. Don’t want to read this article, then listen to highlights how to plaster an old pool in 5 important steps. https://drive.google.com/file/d/0B_ZToeIOgA2sT0xOckJSanNxTDA/view?usp=sharing

First for the tools and materials needed for the project. You will need the mix for pool plaster, acid wash, paint, soda ash, compressor for air, face mask, cleaning solution, finishing plaster mix, chisel, goggles, sump pump for submerging the pool, mixture for cement or mortar, air hammer, normal hammer, yard brush, sander, putty knife, brush for acid, buckets, hose, rubber gloves, wheel barrow, shovel, paintbrush and sponge. Here are the 5 steps to plaster your old pool.

1. Drain the swimming pool, and use the sump pump to drain all the water remaining at the bottom of the pool. Clean the pool of all dirt and debris. Use the sponge and cleaning solution for this purpose. Make sure you use an environmentally friendly cleaning solution for this purpose.

2. Identify the problematic areas where plaster has peeled off significantly. Pay attention to the edges and corners of the pool. Take away the loose plaster with the chisel and putty knife. Sand the sharp edges where plaster has been taken off. Make sure you sand the areas at least twice to make the areas clean and neat for easy replastering.

3. Spray an acid wash over the surface. Use the acid brush to spread it effectively. It will help give you a new surface that is conducive to applying new plaster. Rinse away the acid wash by using a hose. Now allow the surface enough time to dry. Once it is completely dry, apply a bond coat for replastering with the use of a roller. Let it dry overnight.

4. Prepare the plaster according to the manufacturer’s instructions. Now apply the plaster using a street trowel. Start at the deepest end of the pool. You should make sure that the plaster applied is at least 3/8 inches thick. Make sure the plaster is evenly applied on all areas. Now let the plaster dry completely. Mix the plaster finish, and apply it evenly at a thickness of 1/4 inches. You may use the trowel this time round too. Check for any flaws and correct them before letting the pool dry completely.

5. The final step is to apply the pool paint to cover the entire surface evenly. Using the paint brush in one direction will offer a smooth finish to the job. Do not use the pool until the paint is completely dry.

The aforementioned article highlights how to plaster an old pool in 5 important steps.

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