I had all those same issues with my fenders. Finally just opted for the steel version and have had 3 trouble free years. That being said my original fenders made it 9 years....So this showed up in the garage a couple weeks ago.
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With a couple of issues
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All of the welds were done with mig which looked great but were seriously lacking in filler metal.
and my attempt at a fix
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What really surprised me was that it took the full 220A output of my TIG welder to get the puddle started within a reasonable time.
Apparently I was welding on a large heat sink with lot of surface area.
This was probably aggravated by the fact that I had the AC balance set for lots of cleaning action due to the dirtiness of the metal which takes heat away from the weld and puts it into the tungsten.
Also, note to self, turn on the argon before you start next time, burned the end right off a 1/8" tungsten.
@TurboMinivan let me know when you want to pick it up.
I hit it with a SS brush and did not see any oxide breaking up as I started the puddle. Overall I was happy with how it went, other than my shaky hand.For sure the size hurts, but It's the oxidation that takes amperage to break through. If you clean them with a flap wheel and preheat with a torch it'll start at lower amperage.
I had all those same issues with my fenders. Finally just opted for the steel version and have had 3 trouble free years. That being said my original fenders made it 9 years....
bring the other fender and I'll fix/reinforce it while you are hereFor the record, the aluminum fender pictured is 9 years and 2 months old. I think the majority of the cracking was due to it being pushed outward from vehicle (tire) contact during loading and unloading. The other fender also has a crack or two, but they are much smaller and not yet any concern.
Thanks, @frieed! I just need to head up there with the Suburban some time since that won't fit in the 'Vette.
bring the other fender and I'll fix/reinforce it while you are here
Finally had a good warm afternoon so I charged the A/C in my 2wd shorty... It wasnt super hot but I took it on a test drive and had to turn it down, The Vintage air system is Awesome.....
Almost done, Just have to install the new front upper shock mounts, put on the deep trans pan, and of course have Mike put in the rear gears and Truetrac once he gets caught up with all his current projects...
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Let's do this!Let's go ADV'ING!!!