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Originally Posted by GTmike400
I can understand why you would think to use it, and why you would want to use it. 16Gage is often the most commonly available sheet. And you would want to just grind the bumps off. Its a mistake we all make, I'll admit I started with 16 too.
Im guessing your mustang is 18Gage. I might post up some beginner basics on sheet metal forming later on. Im a body boy, your an engine dude, TSC is compositeman, and together we make a great helpcenter for the fabrication forum.
I believe is talking Teg, as in Integra.
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I believe I also fall under the body man also, owned a body shop up till last week when I closed shop to pursue other means of obtaining money (fancy way of saying I got a job that paid better lol)
I would go with 22g myself, but I'm experienced. For a beguiner I would probably recomend 18-20. Japaneese cars are made of very thin sheet metal but it has a very high carbon content so it takes a little welding on it to get used to it. Also be sure to seal it up good after you finish grinding and such because it will rust very easy. The way I do it is pretty much make a form with the taillight but trim it 1/4" bigger than the light itself then use snips to get it down where it barely fits, then hit it with a die grinder to finish shape it, you want it to fit in the hole with a 1/16" gap, that allows room for the metal to expand while welding. As allways when welding on cars and thin metal be sure to just spot weld every 4" or so, cooling in between each one with compressed air or wet rag to avoid warping. Work your way around with spotwelds till it is fully welded.