I would like to take my door handles out and weld in some metal to replace them and install poppers, however, im a BIG newbie to welding. I purchased a wirefeed welder and tried it out on it and that was not good lol. I ended up making biger holes in the door then welding anything. I figured out that I need gas instead of my coreflex wire, that stuff is CRAP lol. Well does anyone have any tips for this that may have done it in the past. Another thing that I noticed was some warping of the door panel, is this normal if it gets too hot? What can you weld the aluminum with? Thanks for all of your help in advance.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by HondaCrazy &raquo;</TD></TR><TR><TD CLASS="quote"> I figured out that I need gas instead of my coreflex wire, that stuff is CRAP lol. </TD></TR></TABLE>

Are you sure your not just bad ? Practice some more.

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by HondaCrazy &raquo;</TD></TR><TR><TD CLASS="quote">What can you weld the aluminum with?</TD></TR></TABLE>

Where are you using aluminum at ? You need a tig.

 

So this is how i have it so far,
your new to welding and you didnt even bother to try it out first before you took it to your car?
not the smartest move.
Ok when your shaving your door handles to keep the heat low use tack welds, dont try to go around the door handle in one shot.
It wont work youll warp the **** out of the door skin and soon have more time invested then its worth.
Have the heat low, due to the really thin metal, thicker metal - higher heat get it?
take your time dont try to rush it youll only make more work for yourself.
Do you have any experience with body filler? because your going use some.

how big are the holes you created?