Welding 101 on ol Curt

[ol Curt]

Well, I thought I would try a small repair using the welder. I had a rusted thru/pitted area at the top of the rear wheel cutout on the bedside panel. I thought I would try to cut it out and butt weld another piece in.

I took the first picture and found the batteries were then dead in the camera. That should have been my first clue, but I pushed on!

I had the batteries re-charged by the time I finished and was quite proud of my first try. I saw one spot that I thought I could make look a bit better if I put a small tack there to fill it in and grind it back down.......that metal is VERY thin after all that grinding!!! What a dumb a**

I guess I'll have another little spot to cut out and patch.

[jonzcustomshop]

try this trick:get a small piece of copper. the weld will not stick to the copper.
clamp it behind your hole, and then slowly fill the hole up with weld.

[msgross]

copper,brass, wood etc... behind the hole... low heat and quick welds...

[ol Curt]

Originally Posted by jonzcustomshop

try this trick:get a small piece of copper. the weld will not stick to the copper.
clamp it behind your hole, and then slowly fill the hole up with weld.

Now why didn't I think of that!

Those sound like good ideas! Thanks guys!!

[msgross]

build it up from the inside of the hole, don't just pile it up like a big bird turd! I do that often enough!

I did a little welding today too...

[scotts62]

And if you do small tacks around the hole you are trying to fill it will work better to. (low heat)

[scotts62]

Originally Posted by msgross

build it up from the inside of the hole, don't just pile it up like a big bird turd! I do that often enough!

I did a little welding today too...

Cool! Are you not going to tack anymore on it? Just curious.

[ol Curt]

This may sound like a really stupid question, but bare in mind I have never welded before this week. Do you guys have the wire actually touching the metal before you trigger the gun, or just close?

[TimE]

Looks good for a first attempt at a repair. Just think, a week ago you were still just thinking about being able to do this. It won't be long and you'll be giving welding advice. Congrats!!

On the gun placement, I usually just get it close but I am not sure what the "proper" way is.

[Inverter]

You want your stick out(amount of wire between the nozzle and the arc)to be 1/2 ",or there about.Clip the wire flush w/nozzle and position your tip 1/2 " from your work ,then angle tip of gun back slightly and press the trigger for a half second only. This works well,assuming wire speed/heat/gas are adjusted propperly. Take your time,make sure any patch material is nice n flush before you tac it.

[ol Curt]

Originally Posted by Inverter

You want your stick out(amount of wire between the nozzle and the arc)to be 1/2 ",or there about.Clip the wire flush w/nozzle and position your tip 1/2 " from your work ,then angle tip of gun back slightly and press the trigger for a half second only. This works well,assuming wire speed/heat/gas are adjusted propperly. Take your time,make sure any patch material is nice n flush before you tac it.

well, that could be part of the problem. I always thought stick out was the amount of wire that was exposed beyond the nozzle. I always have about 1/4-3/8" sticking out when I start.

[Inverter]

Originally Posted by ol Curt

well, that could be part of the problem. I always thought stick out was the amount of wire that was exposed beyond the nozzle. I always have about 1/4-3/8" sticking out when I start.

You are correct.Between the nozzle and your work. Sounds like youve got it.I start around a 1/2" away and,when running a bead,adjust the stick out as needed. For thin stuff you want to make small tacks and move around so as not to warp. What seems to be happening when you weld?

[ol Curt]

Originally Posted by Inverter

You are correct.Between the nozzle and your work. Sounds like youve got it.I start around a 1/2" away and,when running a bead,adjust the stick out as needed. For thin stuff you want to make small tacks and move around so as not to warp. What seems to be happening when you weld?

I seem to still get more popping than it should have. I have been around when experienced welders are welding and I am familiar with the bacon sizzle sound. I feel like I get a better puddle when the wire is shorter and the nozzle is closer to the work. I'm wondering if the gas is doing its job better when I am closer.

[ol Curt]

I have about his much sticking out of the gun when I start...probably 1/4-3/8". It sounds as though I should start with the wire cut off even with the tip but get the tip of the wire within 1/2" of the work.

Hope that makes sense!

[Inverter]

Originally Posted by ol Curt

I seem to still get more popping than it should have. I have been around when experienced welders are welding and I am familiar with the bacon sizzle sound. I feel like I get a better puddle when the wire is shorter and the nozzle is closer to the work. I'm wondering if the gas is doing its job better when I am closer.

That sounds like it may be the gas.Try turning up the flow rate. Sometimes the least bit of draft will disturb the shielding. Ive experienced the popping before and cured it by adjusting the wire speed and or flow rate and or stick out/angle. I started w/the recommended setting of my machine and then fine tuned from there.

[Inverter]

Originally Posted by ol Curt

I have about his much sticking out of the gun when I start...probably 1/4-3/8". It sounds as though I should start with the wire cut off even with the tip but get the tip of the wire within 1/2" of the work.

Hope that makes sense!

That is what I was saying in my previous post.Clip the wire flush and position the tip over your work. That stick out looks like about 5/8" or more,maybe just the photo. 1/4-3/8 is plenty close.

[msgross]

you could have the wire speed too slow if there is still popping... Is your ground good? metal clean?

When the poer is low I find it harder to get that "sizzle" as well..

and yes, I still have to finish welding my corners, just tacked them in till I know that the door is aligned...

[jpz63fleetside]

also check the polarity of the welder. The polarity is changed from gas mig welding and innershield flux core wire welding. if they arent connected the correct way it will pop and sputter.

[Inverter]

Bam!! forgot about that.I remember going through a half bottle of gas before I figured that one out. Good point.

[joe231]

Originally Posted by jpz63fleetside

also check the polarity of the welder. The polarity is changed from gas mig welding and innershield flux core wire welding. if they arent connected the correct way it will pop and sputter.

yeah, i figured that out the hard way

[msgross]

and don't run a cheap extension cord either..

just a thought

[ol Curt]

Polarity is correct!

[Throwback]

when your grinding, try to stay on your weld till you have it knocked pretty much all the way down and that will keep from thinning out the surrounding material and keep that from happening.

[ol Curt]

Originally Posted by Throwback

when your grinding, try to stay on your weld till you have it knocked pretty much all the way down and that will keep from thinning out the surrounding material and keep that from happening.

Thanks Throwback, that sounds like good advice. The thought occurred to me during the process that I might need some practice at grinding as well. Particularly when I got my finger in the way!!

[msgross]

ouch...

I like to use the 60 grit flapper discs for grinding... doesn't take too much away on accident... remember that the more angle that you put on your grinder the more metal is eaten away... keep it flat and moving over the entire area so you don't build up a lot of heat...