Thin metal...grrrrrr.

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  #1  
Old 02-27-05, 07:56 PM
Swat791
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Thin metal...grrrrrr.

I picked up some scrap square tubing from a metal fence compnay.
It was free so I just loaded it up and being very grateful...beggers can't be choosers...the tubing is thin! 1/16" I'm guessing less than 18 ga steel.

Yesterday I started making a front basket rack for my 4-wheeler.

I am using a Campbell and Hausfeld Mig Flux 105 welder
<img src="http://store1.yimg.com/I/pressurewasherzone_1834_15518394">
and it has 4 settings...Low 1 & 2 and High 1 & 2.
I have the welder on Low 1 and feed rate 4 or 5.

I am continually "blowing holes" in the tubing. Nothing that can't be fixed, but the Gorilla weld then needs to be grinded.

If I put the tip close to the metal and feed the wire for a second or two it (tack/spot weld) the metal melts together real nice, but as soon as I grag along it "blows a hole" in the metal.

Of course if I move faster I get an unever weld...if I push vs. pull it helps but I still am "burning holes" in the tubing.

I managed to get the frame built and it looks good and will work very well for toting hunting gear in the field...

Are there any good tips that ya'll have for welding thin metals?


Thanks,
Donnie
 

Last edited by GregH; 02-27-05 at 08:05 PM. Reason: Fix image coding
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  #2  
Old 02-27-05, 08:10 PM
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Donnie,

You don't say what size wire you are using but you should be running the thinnest wire this machine can run which might be .023.
Also, if you are using flux core wire then you will have a harder time welding thin material than if you were using shielding gas.
Gas allows for a cooler weld.
 
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Old 02-28-05, 07:50 AM
Swat791
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Opps...

I didn't mention the wire size...
I'm using .030 in flux core.

Obviously I wasn't thinking of the sheilding gas cooling the metal as I weld thinner metal.

Thanks for the help.

Now I'm headed outside to work on my my project...

Donnie
 
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Old 02-28-05, 10:12 AM
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Donnie,

Ths gas cools the metal slightly but flux core has slightly more penetration capability than gas shielding does.

I actually use flux core with Co2 when working outdoors.
The gas in my case gives a much nicer weld and allows me to weld thinner material.

Aso, one thing I forgot to mention is that you have to make sure the polarity is set correctly for flux core.
 
  #5  
Old 02-28-05, 12:27 PM
Swat791
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GregH,
Thanks for your help.

I used .024 wire and gas (25/75) and set it on the lowest setting.
That work GREAT!!!

I have a cover of the front of my shed and I can block the wind by hanging a canvas tarp on the side the wind/ breeze is coming from. This has works really well for me.

It usually takes me one pass and a wire brushing to figure out I have the polarity backwards when I change from Gas to Flux-Core wire.

I now have the frame completed and I have cut the expanded metal for the bottom...In the morning when I get off work I'll weld the expanded metal in place and add the top rail, primer and painting will be the next step, then I'll mount it.

Thanks again for your help.

Donnie
 
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