Strength before appearance

The trick for making cosmetically discreet, yet suitably strong, weld repairs is as much about getting each element right along the way as it is about learning a special process. The weld only dresses back invisibly when it sits right. The way it sits depends on correct penetration and joint alignment which, in turn, has a relationship to material thickness and to the ultimate strength of the joint. Correct penetration means strength is achieved through the full thickness of the joint so that the weld cap can be gently dressed back without adversely affecting the integrity of the joint. In turn, that joint not only looks right, but is as strong as possible. Technique plays a large part, but that comes with time invested in practice. Develop an appreciation for the details in each step and, in addition to making a discreet weld repair, you’ll be a better welder producing strong joints.

So this isn’t about simply grinding back a weld joint to pretend it’s not there. Instead, we’re showing how perfecting each step adds up to the end result being cosmetically much better as well as being a competent repair.

When Aristotle said ‘‘excellence is not an act, but a habit’’, he may have been welding his Land Rover. Because with welding, if you try to hide poor workmanship, you’ll make it look even worse. To get your welds to disappear, focus on getting everything ‘right’ along the way. Part of the reason welds disappear after dressing is because the welds have been correctly achieved, on a correctly fitting repair panel. It is as simple as that.