Get 220 volt with gas. Easier better welds

 

More or less a safety concern, but does the gas tank need to be removed? I have an EVAP leak, so would kind of rather not blow up my car... Will the fluxcore welder ignite the potential fume from the tank? I understand that the flux releases some gas to prevent oxidation, is it enough to keep the gas tank from exploding though? Could I just siphon the tank and then remove the cap and let it dry out for a few days?

 

After you weld, you'll be grinding the welds, so any tiny little bit of corrosion that might start will get ground back off the surface.(you'll want to hit the backside with a wire brush to clean before priming) Just make sure to protect the bare metal with primer if it's going to sit for more than a day or so, or if it's going to be exposed to moisture. A couple coats of primer is enough for corrosion protection. (4-5 is what you'd want over your bodywork)

As far as the fuel tank, I would just hang a welding blanket to block Sparks from the tank/EVAP box if you're talking about doing the quarter panel....If you're talking about while welding the bumper, it would probably be easiest to just remove the bumper and doing the repair off the truck. Also, always keep a blowgun handy to blow out any small flames from paint around the welding area that may occur.