Check out my welding

[norske]

Got a new welder from harbor freight and trying wire feed (no gas) welding for the first time. As you can see, I suck. Can anyone tell by the pic what my major malfunction is? This is an old box side that's going to the junk anyway. Tried different speeds, kinda looks the same, minimum setting.

[silverstreak]

I'm not a professional or an authority on welding by any means but all those craters come from not have any sheilding gas to protect the puddle. It will be easier for us to help once you get some gas so we can see what you can really do.
Those large holes are where the heat was too high and the puddle just blew through. For a butt weld on sheetmetal, it's best to take your time and just do a series of spot welds. Pull the trigger for about a second, let it cool for a few seconds or jump to another area then zap it for another second. The long "stack of coins" type of welding is used on much thicker material.
Keep practicing, you'll get it in no time. We all started out doing the same thing.

[Number98]

Are you using flux core?

[prostreetC-10]

First of all.....you should try opening your eyes!!! LOL

Just kidding and that's how you learn. I'm not sure how the chinese welders do but you need to weld with the flux core wire at about .035. I learned on that but once you weld with gas you will never go back!!!!!!!!!

....and farting on your weld is NOT what I'm talking about!

[zeeklu]

Grinding the area clean to bare matal will help. Chris

[norske]

I'm for sure staying in one spot too long. Farting is the only gas I have for this welder (not capable). I did clean the area with a flap wheel first. Should I stay at a minimum wire speed?

[68gmsee]

Problem with gas is that you have to be in an area where there's no wind. Preferably in a metal building or similar. I agree that it's the way to go if you're welder is set up for it. If not, just keep practicing using different settings, vary your speed, and/or try different wire sizes.

Welding is a learned process and takes practice -somewhat like painting. One of the things I've learned on this site is that if you really want a good quality weld, you have to buy a good, quality welder. So, I'm still holding off until I can afford one.

[prostreetC-10]

zeeklu reminded me of something. Your ground is extremely important. Can't clap onto paint. You really should sand off a spot so you can clamp to bare metal. I'm guessing this is a 110 welder? Electrical supply can make a difference. Try to plug into a clean outlet with no other items plugged in and stay away from extension cords!

[Number98]

All of these are good advice.

Minimum wire speed is also not always the best way to go.... as the puddle heats and the base material begins to melt you will need to add "enough" wire to fill the keyhole... thus speeding up the wire some will help fill in this gap.

Practice, practice, practice.... you will have to "play" with your welders settings some until you find the best settings for the material you are working with. Not all welders will react the same so get to know yours.

[norske]

Cleaned a spot to bare metal for the ground but was using an extension cord. Will eliminate the cord. The ext. cord did have a ground on it tho.

[John Pasinski]

.035 is too heavy for that sheet metal. In order for .035 to meld w/ the steel you must get it way too hot. That's why you must use something thinner, say .025. Flux core can be a bear but that's all you can use SOMETIMES outside if it's windy. It's much easier to learn with steel wire & gas. Also, I'm a "spend the good money up front" kind of guy when it comes to tools, ESPECIALLY big ticket stuff. You'll have it much longer, & you'll have less problems. For the truck sheet metal, spot weld, move a coupla inches, spot weld, move a coupla inches, etc. Until you get it all filled in. Then grind it down and fill in the low spots. Then grind some more. Patience & practice.
There's an old question that goes: "What makes a GOOD welder?..............A GRINDER.
Keep practicing. Go to:millerwelds.com You'll love it

[prostreetC-10]

You are right on the .035 John. I got my wires crossed. It's REALLY hard to weld good into just a thin gague as sheet metal with flux core. You really need to try and get gas!

[norske]

I'm using .039 at the moment. Should I drop to .025?

[norske]

I mean't .030, not .039.

[dwaite72lnghrn]

You need to be at bare metal all around the weld area front and preferably back. I would start welding with the panel upright, It is easier to get the right angle with the gun and practice/practice/practice. The smaller the wire the less burn through, Around here it is near impossible to get anything smaller than .035 flux. With sheet metal you really don't want to "run a bead" you want many many spots to close a seam.

[crushermechanic]

find you a thicker piece to practice on until you get the hang of the welder. flux is very difficult to weld sheet metal with. weld prep is very important clean all paint possible off. practice lots.

[bad6772]

all great and sound advice....And I would agree...Switching to gas would help a lot...And making sure you have a good clean ground is number one...And make sure the pieces to be welded are oil and paint free.....Flux core does have its place...And for the most part...Its not on sheet metal....Good Luck and practice.......

[oldblue1968chevy]

you need GAS man! after that and cleaning the metal its not too bad watch burnin those holes there a pain to refill LOL

[john8746]

here you go check this out
http://www.mig-welding.co.uk/
may give you some ideas

[chas350]

x3 on clean bare metal before welding, its that important! you will notice a HUGE difference. Practice

[jojo]

I too ran the flux core welder from harbor freight for a few weeks before giving up and buying a gas unit. Sheet metal is too thin for the flux core (at least for me anyway). Burn through all the time. I'm sure some people have made quality flux core sheet metal welds but I'm not sure how.

I took the new gas welder home and was making acceptable welds by the second session. You'd be surprised what a difference it makes.

Also I haven't seen any flux welding material that's thinner than .035. After switching to gas, I started with .025 but quickly switched to .030 after getting the hang of it.

[Deaol]

I use a argon / co2 mix with .023 wire using my miller.. and it welds body panels beautifully.. remember that you need to weld in short bursts and distribute the weld and really watch your heat.

Speeds and phase differ on what type of metal, alot of reproduction panels are cheap chinese thin diameter steel.. american made panels are alot nicer to weld and normally are slightly thicker and closer to the original.

[ol_skool_chevy]

throw the wire that came with the welder away..its crap.....go buy some Miller or lincoln wire.....thats Horbor freight wire is just crap....its a ok home hobbie welder just get rid of the wire

[GASoline71]

You need .025 wire and your prolly too hot as well. Proper surface prep is a must.

I weld up to 3/16" with .025 and shielding gas... just do a little swirl action to grab metal...

The cheap made welders with no gas welding and flux core wire really arent set up to well to do sheet metal... get a couple hunks of 1/8" angle Iron or flat bar and you'll notice it's easier to do.

Gary

[norske]

Gas isn't an option right now (cash), so I'm going for the quality .025 wire for now. There's more and better detailed info on this thread than any article or web site that I've ever seen. Good stuff guys!