Thanks, Jones... Cody Samuel Jones...(insert James Bond music...) Here's some pictures of me experimenting with Lead (a.k.a. Body Solder). The driver side door is pretty "Swiss cheesed" with cancer. unfortunately, I got "Champagne tastes on a Beer budget", so I'm gonna try to patch the doors first before I spend $400.00 bucks on door metal from aftermarket vendors... I soaked the door for a week in the Evaporust, cleaned the dried up residue off the door skin, used the propane torch to burn out the residual in the cracks and trimmed out some sharp metal pieces. I then sanded the lower door area, tinned the copper patch piece, cleaned the door again, "tinned" the door metal, cleaned the door again, welded the bottom edge back together, and commenced to making a mess with Lead sticks. after that I began to File down the lead to an acceptable shape, it will need more lead to be applied but I ran out of time and had to go to a family event.
The right way to repair this door is to weld in "new" metal skins and cross members, but I am being Miserly and experimenting at the same time...whats the worst thing that could happen, the patch crack-up...then I'll just have to cut/weld replacement pieces in.
The Leading area has low spots in it and will have to be built-up with more lead, but I was getting low on Lead and time so I called it a day, went home, and ordered more lead...I used about 4-5 LBS on that spot. I would say Aprox. 1 lb was lost to Filing and Drippage of molten lead.
I am just trying to fill the lower door panel with lead using the Copper plate as a anchor to bind the remaining door steel onto the copper and fill the massive gaps with lead instead of "plastic" filler. As I said with the same type of patch in the cab, I am not sure if this is gonna hold in the long run, but I haven't really ran across any "Old Timers" to ask about Lead...I haven't read about trying to patch like this it just another experiment so Standby to Standby...
1942 G7117 no. U.S.A 389946 Serial no. 9NM 22 3669
1945 G527 250 Gal. Springfield Auto Works Serial no.9218
Navy Seabee CM3 NMCB "4" 1996-2001
Caterpillar Field Service/Used parts Dept/GPS Grade Control 02-Curr