After the wiring and installation comes the more time consuming process of shaving the door handles. And that is actually the shaving part. We tried two different methods on this Camaro. On the passenger's side, I cut out the keyhole and the handle as one piece and created a patch panel the exact size then MIG welded it in. On the driver's side, smaller patch panels where the door lock and handle used to be were fashioned and welded directly over the holes. The later was the best method. I'll explain why in a minute. Before we go any further, we wanted to introduce to you the latest and greatest TIG welder from Miller, the Diversion 165. Yes, it is a home hobbyist TIG unit. It has only three switches. One is the power switch, the other that is the AC or DC for either steel or aluminum welding, and the other is the metal thickness dial from 22-gauge up to 3/16-inch. That is it. It is a perfect companion with the smaller Millermatic MIG welders. What is also interesting is the fact that a foot pedal for this home TIG unit is optional. A power switch is built into the gun itself and that controls the arc from the tungsten.Before we go any further, we wanted to introduce to you the latest and greatest TIG welder But why use a TIG welder? It takes more time to learn and requires the use of both hands and usually a foot. A big reason is weld profile and weld penetration. In this photo Jeff Martin uses the Diversion 165 and TIG welds the patch panels on the driver's side. Since my TIG welding coordination skills are still in the embryonic stage, I let Jeff handle this.But why use a TIG welder? It takes more time to learn and requires the use of both hands a If you notice the circle patch panel, a small portion of it was MIG welded while the rest of it was TIG welded. The immediate difference is the weld profile. The TIG process lays a flatter weld puddle than the MIG. The arc from the TIG welder is more concentrated and does not disperse as much heat as the TIG. That's not to say there is no danger in warping the thin metal doors, because warp they did despite our best efforts. The door skins are approximately 22-gauge metal. Metal that thin can build up heat in a hurry and warp if it is not cooled down quickly.If you notice the circle patch panel, a small portion of it was MIG welded while the rest The passenger door was all done using a Miller MIG welder. Notice the profile of the welds when compared to those of the TIG welder. A lot more grinding is required when a MIG is used over a TIG. Even though it took me nearly two hours to stitch this patch panel in, warping did occur.The passenger door was all done using a Miller MIG welder. Notice the profile of the welds Warping on the TIG side (driver's side) was less than the passenger side. Even though warping occurred it was mild and easy enough to deal with. Armed with a body hammer and dolly and nail gun, the doors were straightened back out as much as possible, then body filler and a high-build poly primer were used afterwards. This is where most of the work comes in. Lots of time and sanding is required after the welds are ground down.Warping on the TIG side (driver's side) was less than the passenger side. Even though warp Here is a closer look at the Diversion 165. Our web site also contains a more in depth look at this new TIG welder.Here is a closer look at the Diversion 165. Our web site also contains a more in depth loo This Camaro will eventually be repainted in Hugger Orange and the door bump guards will be removed, the antenna will be shaved, as well as the gas door. Follow the future progress on this '88 Camaro at www.superchevy.com.This Camaro will eventually be repainted in Hugger Orange and the door bump guards will be SOURCES Miller Welding Equipment Electric Life « | 1 | 2 | 3 | View Full Article By Mike Harrington Enjoyed this Post? Subscribe to our RSS Feed, or use your favorite social media to recommend us to friends and colleagues!