How To TIG Butt Weld Sheet Metal 1939 Zephyr 

You have the most honest metal working videos out there. You don't just say "...and then I magically use the English Wheel.." . You show a decent amount of time lapse video. You show the actual work that goes into it. This shows that it is not simple, but if one puts in the time, it is possible for the common person to get the desired results. Great work! Also your ability to describe the work and your thought-process is amazing!

I can't get enough of this. Just like any other form of welding prep makes all the difference. Truly a master of your craft!

Karl, once again you have totally killed it! Your thoughtful approach, skilled shaping and fitting, and obsessive attention to the details is truly impressive. This old man really appreciates the time you take to do, tape, edit, and comment upon your projects. Thank you for sharing this with us. Also, I dig the sick beats you mix.

Karl, another fine job. Your devotion to perfection defies description and is unequaled by most. I just am in awe in watching how you can work that metal and hope that with a lot more practice, I hope I can become better. I'm able to pick up a lot of tips from you. You are definitely "Da Man".👍

As a bodyman of 30 plus years Karl, I’d be honored to work behind your metal work. You do an excellent job of fabricating every panel you make. I haven’t ever worked panels behind anyone else who puts in as much effort as you do. And I’ve done A LOT of bodywork. I see how well you do things, but I don’t think I could do as well of a job as you do. Thank you for all the work you show me/us. Much love and respect my brother 👌 👍

Loving the Zepher project! Keep up the great work!

WOW, now I want to cut my project apart and start over. 😢

❤You are awesome Brother and thank you for sharing!🎉

Great craftsmanship! A wonderful conversion. Thank you for sharing.

I really enjoy the fact you mention those I also follow, in learning technique myself. Ron Covell does some really good techniques for "clean up". Moving back and forth side to side is really showing off the "last little bits" that substantially change the fit and finish. Your gauges and handling really show off the ripples and form in the panels that aren't visible at first. I wouldn't've have thought to run the weld that long on sheet metal if I hadn't watched you do it. I really enjoyed watching the weld simply roll along that seam without any bulge to speak of.

You hit another one out of the ball park Karl! Well done 👍

I know I've said some thing like this before, but I'll say it again. I would have no fear of buying a vehicle you built. I think your a not only a great builder but also an honest one.

I have never commented on any RU-vid video before, but this video was so good. The best instruction in my opinion on welding sheet metal. Thank you for all the detailed instruction.

Excellent video. It's been done time since I Tig welded, and bitched a customer job today, so this was a super good refresher.

Masterclass! And way to keep it interesting! ⭐️ ⭐️ ⭐️ ⭐️ ⭐️

Amazing work Karl. You won’t need much filler. Filler work is easy when the metal work is perfect!

I'm really really really waiting to see the lid going back on and being made!!!!! Well done Karl you da man!😎🙏👍👍👍👍👍👍👍👍👍

Watching your work makes me way too comfortable with the idea of cutting up the body of my project. I'm very likely to end up with a giant pile of rusty metal parts that USED to be a late 50's Cadillac. 🤣

Very many thanks for this excellent tutorial! And many thanks for taking the considerable extra time and effort to video the whole process, many videos show the start, then the finished product, that gives no instruction at all, your excellent presentation shows start to finish, and also step by step "secrets" of a successful weld, a really useful video to watch many times! Chris B.

I'm glad to see this one coming together, I'm sure you are too, nice work Karl, get-er-done

This is the video I needed to learn why I struggled with the bodywork on my Lada Niva. Thank you very much for teaching me to do much more tacks. Never stop making those instructional videos! Greeting from Germany

Try heating the metal from the opposite side of the tarand it will let go with less heat. Just a tech tip you might want to try Karl. Looks great !.

good job dod Tig welding is a good job i learn some touches from you. Thank very much for videos you give us

Another great day at school great explanation Karl. Thank you

I watched every minute and even went back a couple times and re-watched a few sections! Seems like a lot of people shared their level of experience, I'm a former aircraft structures mechanic and helicopter pilot. I rebuild my own helicopter and built several home built helicopters in New Zealand before I worked here in Tucson at Bombardier and Mitsubishi Regional Jet as mostly corrosion repair or replacement of structural frames and dent repair or replacement of exterior skin.

Karl, you should use lead instead of bondo then you could call it the “Lead Zephyrlin”. Keep up the good work you are a great inspiration to us all.

Hi Carl, Love the channel. (a small complement from the Netherlands:) You look ever so artisan in your leather apron. 😊

Hey Karl, as always you make the difficult seem easy. Your tutorials are so instructive. The Zephyr is progressing nicely. Thanks and we'll see you next time.

Karl Your manipulation of thin sheet metal is super....saw a pic of a zephyr one word came to mind SMOOOOTH ....🙂👍🙏

Always a pleasure to watch you work your craft. Motivates me to tighten up on mine.

One knows their craft when they can describe it and demonstrate it Drop Dead Perfection

Karl, Just catching up on your videos after being away. Great tig advice. Looks fantastic.

Jay the Florida pool pump motor repair guy. When Service Calls Longwood approved ! that was good info 2 see& know👨‍🔧good job !! MIK

It looks so simple and yet I struggle hard! Thanks!

This is an amazing project and you are an amazing craftsman.

I’m currently working on door flanges and skins on my ‘83 Caprice. 18ga and 20ga respectively. So far it’s moving along.

glad to see you back on the 39 ,looking good 🙀

It looks great, and I love your music when you go to higher speed.

Love your "let's give this a try" even if your not sure how! LOve vids...all the bset! Be safe!

THANKS its always great to learn from the MASTER

This is coming along so nicely. Also, you know you're making it when @roncovell is checking out your vids 🤘

I discovered fusion tacking with a timed 1/2 second burst at high amperage works so well. It tacks the panel pieces together perfectly and avoids the usual scenario of the tack shrinking and causing the panel joint to pull over itself too tight, and the two pieces to pull out of co-planar. I saw a ‘cold welding’ RU-vid short video and tried setting my Tig up to replicate. It works so well. I use 1mm steel mostly. No need to hammer and dolly the tacks at all. Please try it. You will love it!

a diesel soaked rag does a great job of removing tar residue after you're done scraping...so you don't load up your wire brushes/paint stripper wheels. I learned that cleaning up more recent GM truck frames. I can't get enough of your channel. Maybe I can stop by your shop one day and shake your hand. I've learned so much on here.

Thank you for explaining the thicknesses, amperage, and your thought process about the settings you are using on your welder and details about the consumables you are using. I think you are the best in class at what you teach. Thanks for sharing your talents.

I really like that you show all details and the importance of preparing the parts properly-it is an art to weld well and preparation is key - well done

Awesome content I'm learning alot

Nice work Karl. I've seen a lot of siberian huskies with one pretty blue eye and one brown.. Cool pup.

KARL you are a LEGEND !!... The tips I get from your videos really helps me with my beast !.

I want to take a minute and thank you Karl! I just hit 104 subscribers on my channel today, and I have you in part to thank for that. I have learned a lot from you and more than that, I have been inspired to continue going on with the channel when I have considered quitting. It has taken awhile to reach this number, and to some people 104 subscribers is not many, but it's a huge number for me considering I wasn't really expecting many, if anyone would be interested in following me. Especially since my channel started out with just my 69 Camaro build, then starting a C3 Corvette build as well, making my channel more of a niche narrowing the number of interested parties. I have added a few things extra in the meantime, but without channels like yours I would not have kept going, and not be seeing promising results from the work put in. So thanks again! And I gave your channel a shout out in my video that I just posted tonight, and the reason why

I am really amazed at your metal working capability. I wish I had watched your channel before I started welding by truck . Good job.

Years of practice makes you an outstanding craftsman. Love your abilities.

Absolutely love your metal work quality.

I learned a lot here, thanks, you really have a lot of talent.

Great work Carl. Can't wait to get you to do the metal work on my 41 Ford truck. Lol

thanks for showing us what ya do. nice work. thanks.

Really impressive work! Knowing how metal will react to heat, welding, is only gained by watching makeitkustom or years of experimentation! Love your videos Karl!

If only more people could understand exactly how much skill it takes to do that. Thanks for the video.

Great detail in how you do it. Probably the best TIG video you have done which is no mean feat. Thanks for sharing and helping make us better.

Smash that like button! Making perfectionists feel slovenly. . .

You are very skilled because of your desire to learn and hands on experience. You learn every time you put your hands to something. Thank you for sharing , and helping. It's not easy but it can be done.. love your channel please continue learning, teaching, sharing.

G’day Karl,long time watcher of your vids,first time commenting. Most impressed with all your work maté especially the Zef,can’t wait to see her finished. Not sure if you’re familiar with the Aussie muscle cars,but you’ve inspired me to do the rust repairs on my 1974 XB GS Ute. Keep up the great work Cocko Cheers

Wow,it's all in small things that help alot info..tks for sharing, looks killer

Great vid good info happy new year to you and your crew from an old timer ,central coastNSW Australia 👍😎

you are a true craftsman love your content

The only channel, the only videos , that I can an will sit still an watch. Your videos could be three hours and I would just sit an observe your skill . ❤🔧😎

You show and teach very well. Can't wait to see more videos soon. Keep up the great craftsmanship and hard work my friend. Fab On. Weld On. Keep Making. God Bless.

As i watch more i understand more. This old dog is learning new tricks… Tig, more malleable than mig. Sure like how it turned out karl!

Loved it, The camera above the long weld was Awesome! As you were welding I kept watching the top edge of the metal to see if it moved, I was impressed to not notice any movement. Thanks for stressing how important fitment is before welding!

Top quality work on both metal forming the panels and TIG welding them in. Excellent 👍👍

Really enjoying watching the progress on the Zephyr Nice work looking forward to seeing more Cheers Frank

I didn't notice that spot weld drilling method with the small bit and bigger bit. Cool trick

Thank you. Excellent lesson.

Love the fact that you take the time to explain the process. Looking forward to more videos on your Zephyr man!

Just crazy how solid that car is for it’s age, vehicles don’t last 20 years around here and they’re just rusted away to nothing. Great series, really love this car 👍 tell Brenda I says hi! 😍

Fabulous job Karl!

So cool to finally see some progress on this car. You're a busy fella. And hopefully the caddy again soon.

Karl, When you wheel a panel like that as you raise the center up the edges want to draw inwards. So if you cleco the panel in place (all along the edges) to check the shape then take it off and wheel more you have to force the edges back in place to cleco them again. So this draws a little shape out of the panel that is part of the reason why your getting the lows either side of center when you check the shape on the car. You can get there doing it that way but it takes longer. You would get the same effect if you layed that panel down on the bench and gently pushed down on the center of the panel. It will show less shape when gently pushed down then it will when not pushed down. try using one cleco on top and reference marks along the edges until your near done with the panel. That would allow the edges to fall in there natural location. Then you will get the shape your going for faster.

Karl your so great at body work. Love seeing your talent. Thanks for sharing!

Hey Karl, Great build series. Could you add a photo/rendering of what you started with, ie 4 door Zephyr, plus a photo/rendering of what an original 2 door coupe looks like, plus a rendering/photoshop version of what your vision is for this project at the beginning and/or end of each episode, Kinda like what you've done for the COE ramp truck project? Thx

Karl another great job 😄.

Amazing - I haven´t seen it done before, just ready jobs without paint on exhibitions. And we can learn a lot, if we ever try seemless, not just spot-welding in body-parts!!!!! And though it takes a long time in your video it´s not boring at all. nice music in background too. 🤪🤓- You´re a pro

Thanks for showing the back of the panel after welding Karl 🙂. It was good to see the penetration 👍

Your boundless tenacity never ceases to amaze me, Karl. Such phenomenal attention to detail with an abiding passion for your craft. It's like watching a sculptor working on a masterpiece.

Very interesting. Another great soundtrack.

Best welding video I've seen in a long time. Thanks!

I’ve probably said it before, amazing craftsmanship! Thanks Karl!

Thanks for teaching this, I am about to do some tig welding on my roof and I a nervous about fitting the curved panel and burning through the sheet metal. This is very helpful.

I'm a finish carpenter. I know nothing about sheet metal work. But I appreciate craftsmanship. Your work is amazing to me...! I'm very curious about how the English Wheel works.... Great video!

Beautiful... I'm Sooooo Glad to see more of the Zephyr... ❤❤❤

Beautiful work again, thanks for the info about amps and other details! Those really help ppl when, when figuring things out.

Your dog reminds me of my dog Max lol; couldn't find a better natured dog! very cool!

another super video, the patience and skill is something to see

This is a really good video. You sir are very good teacher and a great artist on automobiles. I can't wait until it is completed. Looking forward to your next video on the mercury

Beautiful work Karl! All the time spent fitting really pays off when it comes time to weld. Keep up the good work.

Love your stuff bro! Thanks for sharing and keeping us updated on the Zephyr!

Excellent video giving lots of insight into the fine points of sheetmetal wizardry that you are so awesome at!! Definately a master of the trade and what keeps me watching, you are excellent at explaining what you are doing and highlighting the most important parts!

You guys play the best background music on YT

Looking great, certainly coming together, all the best to you and your loved ones

Always nice to run downhill whenever you have the opportunity. Great approach and execution Carl! Put up a sketch to show the ultimate goal of the finished look you're shooting for. 👍😃

Really appreciate you providing your insight as you work through. Really inspirational