Older Suzuki Vitara’s have a reputation for rusting, well the bodies anyway.
When I bought Tugg, I did miss a couple of holes near the rear seat mounts. Now removing the seats was an option but would mean notifying DVLA this would not be an issue for the MOT or annual road inspection. But then Tugg would become a commercial vehicle and that would affect insurance etc…
There are a few basic rules to welding, the first is that any hole will be far bigger than it initially appears. Many years ago when welding a friend’s Ford Escort after tapping a small area almost 2 foot of rust landed on my head and in my eyes… So yes the holes did appear a little larger than expected, but not overly so.
After being taught to weld by a friend 10 years ago I enjoy it much more a lot of mechanical work. I still use the same second-hand Cebora 130 Mig welder I bought then. Over the years I’ve welded on a fairly regular basis and have slowly increased my skill level.
Along the way, I’ve acquired a few tricks. One is to disconnect the battery. This is becoming increasingly important with the increase in sensitive electronics. Perhaps the most important trick I’ve learned is to prepare the metal really well. I use sanding disks on my angle grinder as they give a better finish than grinding disks.
Having prepared the areas that required welding I started work. After cutting a patch to fit I then spot welded it into place. Metal expands and contracts as heat is applied, so almost fitting is good enough in the tacking process. You can either hammer down each section as you work along the edge or press down using an old screwdriver. Once the patch is spot welded in place it is simply a question of then joining them up using little beads of weld. To avoid overheating an area it is best to weld on alternating sides of the patch. I was taught to weld on the lowest setting to avoid blowing holes in the metal. Sadly this means that good penetration is not always achieved. With experience, I now weld on a higher power setting.
Once done, I ran over the welds with the sanding disk. With a coat of black paint, the job looks fairly tidy for MOT test next Thursday.
Yes, the holes are a little bigger than expected, but now they are done.
A good afternoon’s work.