How To Weld Aluminium Car Panels. Cutting the panel away and replacing the corroded sections would be a tricky option as the panel is rather complicated. Amperage settings are critical when MIG welding sheetmetal.
Youll need some metal left to weld the replacement panel. Using hammers dollies and picks when access to the backside is obtainable is a very common practice for straightening. Turns out you can weld aluminum without a welder.
For welding an oxy-acetylene torch is required to join for example two butting edges of flat plate or one channel section to another.
With areas of limited access to the backside using a weld-on dent puller for straightening is also quite common. A lot of restorers just make new lower sections for the wings. If you are thinking about restoring a car then hopefully this section might provide a little inspiration. Practical Welding and Body Work.