Black_Cat's Bumper to Bumper Build Thread - Page 2 - TCCoA Forums

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post #31 of 41 (permalink) Old 07-25-2016, 08:07 PM
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Originally Posted by Trunk Monkey View Post
Welds look good for the most part.

There's a goober (welding term) at the tie-in in the first weld picture that should be ground out and blended.

There's weld splatter (spatter) in the next to last photo. This is really a non-issue.

There's cold roll (lack of fusion) at the lower right side of the weld in the last picture.

It doesn't look like he did any surface prep work. The accessible welding locations should have been ground clean down to bare metal with a wire wheel prior to welding.

After welding they should be wire wheel or wire brush cleaned again for inspection.

First photo - Grade B - Poor tie-in
Second photo - Grade C
Third photo - Grade C - Again - poor tie-in at the corner
Fourth photo - Grade A - Good weld in a tight location
Fifth photo - Grade C - Cold roll

Overall Grade C

Trunk Monkey - AWS CWI

If we have any welding done here I'll show you what our welders are capable of. They never cease to amaze me how good our welders are.
Surface prep? lol. When someone grabs the E71T-11 flux core, ain't no surface prep happening!! A lot of those locations are in-accessible to any wire wheel of a decent size. Some of them are in deep "V" grooves, but that don't actually meet up at the root, sorta like open-root pipe welds. Flux-core is a stupid hot process, so I am willing to bet those welds are indeed solid, despite the lack of prep and some bumps here and there. They [beads] look like they're about 3/8-7/16" wide at some points, so that means those are about 1/4" leg fillets----a lot of metal indeed. What I really like is how little spatter BBs there were! That means he ran a good wire, probably a Lincoln 211 or 212 Innershield.

The only way some of those joints could be cleaned out is with some 6" long-shank carbide burrs with narrow 14° "christmas tree" cones. The IRS is not flimsy by any means, anything extra is just icing on the cake and not from the initial recipe for structural soundness. I've seen some really crappy factory welds on both my IRS subframes that makes me scratch my head . I wonder if the welding on our subframes was 100% automated. Anyone know?
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post #32 of 41 (permalink) Old 07-25-2016, 10:39 PM Thread Starter
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Surface prep? lol. When someone grabs the E71T-11 flux core, ain't no surface prep happening!! A lot of those locations are in-accessible to any wire wheel of a decent size. Some of them are in deep "V" grooves, but that don't actually meet up at the root, sorta like open-root pipe welds. Flux-core is a stupid hot process, so I am willing to bet those welds are indeed solid, despite the lack of prep and some bumps here and there. They [beads] look like they're about 3/8-7/16" wide at some points, so that means those are about 1/4" leg fillets----a lot of metal indeed. What I really like is how little spatter BBs there were! That means he ran a good wire, probably a Lincoln 211 or 212 Innershield.

The only way some of those joints could be cleaned out is with some 6" long-shank carbide burrs with narrow 14° "christmas tree" cones. The IRS is not flimsy by any means, anything extra is just icing on the cake and not from the initial recipe for structural soundness. I've seen some really crappy factory welds on both my IRS subframes that makes me scratch my head . I wonder if the welding on our subframes was 100% automated. Anyone know?
The guy who did my welding (who is also a welding instructor), said all those welds were hand-welds, and he said 90% of them were questionable lol. He said sure they would get the job done, and probably passed QC, but it wouldn't pass his QC...

I drive an endangered species...they are being crushed at an alarming rate. Please do your part to preserve the Cougar species, and ensure they live on into the future.

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post #33 of 41 (permalink) Old 07-26-2016, 04:52 PM
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The guy who did my welding (who is also a welding instructor), said all those welds were hand-welds, and he said 90% of them were questionable lol. He said sure they would get the job done, and probably passed QC, but it wouldn't pass his QC...
Yea they sure don't have the consistency of even partial automated robotic welds. Can you ask that guy if he happens to have a lead on a Smith or Miller Argon/Helium Proportional mixer? I'm looking for one at a good price.
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post #34 of 41 (permalink) Old 07-26-2016, 06:37 PM Thread Starter
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Yea they sure don't have the consistency of even partial automated robotic welds. Can you ask that guy if he happens to have a lead on a Smith or Miller Argon/Helium Proportional mixer? I'm looking for one at a good price.
Yeah sure thing, if I can find his number in my phone...it got deleted somehow and I have more work for him lol.

I drive an endangered species...they are being crushed at an alarming rate. Please do your part to preserve the Cougar species, and ensure they live on into the future.

1995 Mercury Cougar XR-7 4.6L 2V 5 Speed
1998 Lincoln Mark VIII LSC Collector's Edition Car#94
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post #35 of 41 (permalink) Old 02-24-2017, 10:49 PM
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Surface prep? A lot of those locations are in-accessible to any wire wheel of a decent size.
That's what sand blasters are for.

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post #36 of 41 (permalink) Old 02-25-2017, 05:47 PM
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Any updates on this build Ian
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post #37 of 41 (permalink) Old 02-26-2017, 06:43 PM Thread Starter
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Any updates on this build Ian
Not a whole lot buddy, just rewired the Speedcal to the Run circuit from the cigarette circuit (always hot) it was draining the battery constantly. Threw a new Motorcraft battery in it, and I got the new carpet in it and dash back in...carpet needs a professional deep cleaning, and I'm waiting on msp252 to do his engine swap so I can throw a set of PI heads on, new exhaust manifolds, and a fresh oil pan gasket. Should give me a good bump in power and be nasty. Bad news is, we had freak hail here the other day from a storm cell, I have 4 small dings on the roof, and two on the trunk deck-lid. Good news is I had my Mark VIII with me and was out of town so the Collector's Edition is safe!

I drive an endangered species...they are being crushed at an alarming rate. Please do your part to preserve the Cougar species, and ensure they live on into the future.

1995 Mercury Cougar XR-7 4.6L 2V 5 Speed
1998 Lincoln Mark VIII LSC Collector's Edition Car#94
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post #38 of 41 (permalink) Old 02-26-2017, 07:30 PM
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Blah, the Mark is already dimpled by design, poor Cougar

-Matt
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post #39 of 41 (permalink) Old 02-26-2017, 08:23 PM Thread Starter
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Blah, the Mark is already dimpled by design, poor Cougar
They aren't bad, and can probably be pulled out pretty easy before I get it repainted in 10 years. The Cougar is really on hold until i get the Mark where I want it. Check out the plans in the thread, I'm about to update it with pictures and such. Won't take much, I might just take out a personal loan to get it ALL effing done at once and call the car done.

I drive an endangered species...they are being crushed at an alarming rate. Please do your part to preserve the Cougar species, and ensure they live on into the future.

1995 Mercury Cougar XR-7 4.6L 2V 5 Speed
1998 Lincoln Mark VIII LSC Collector's Edition Car#94
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post #40 of 41 (permalink) Old 02-27-2017, 06:52 PM
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Sorry about the hail dings, thank god I got garages to keep my Cougars in and it don't hail in Florida
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post #41 of 41 (permalink) Old 03-02-2017, 06:55 PM
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That's what sand blasters are for.
True, but most people don't have air compressors with big enough ballz to do sandblasting.
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