I finally bought a $300 stud welder and my $40 one was just shredding panels
Spent 6 hours last Tuesday fixing pulled studs and crushed metal on a Civic fender in Dallas, all because I cheaped out the first time. Anybody got a decent trick for keeping the ground clamp tight on rusted rockers?
Man, that tab trick sounds slick in theory until you're on your back in a Dallas driveway with rust flakes raining on your face and no clean metal anywhere in sight. On those old rockers the steel is so thin and pitted that tacking a tab just blows a hole straight through, and now you got two problems instead of one. Honestly I'd rather spend ten minutes grinding down to good metal and cranking the clamp on that bare spot, at least you know it'll hold. Your mileage may vary though, depends how far gone the metal is.
Why not just tack a little tab of clean steel on the rocker and clamp to that instead of fighting the rust? Takes two seconds with the welder you already got and the ground actually bites. Rust never holds a clamp worth a damn no matter how hard you crank it. Grind a small spot to bare metal if you can reach it, that helps too.