J33pMan's Adventures in Welding

[JustinWC]

Nice work ... Its funny the uses for filing cabinets. I have two of them in my roll around bench!!

That's absolutely correct. I just obtained one to house my cnc package and computer tower to run my CNC table.

[J33PMan]

Got my welding table on its feet tonight. So I thought I would share. Still need to paint it (not the top of course) but couldn't wait to post it.

These are all scrap metal from the local yard.
All 3 projects so far. Welding cart, clamping square, and welding table.

[J33PMan]

Ok, I am pretty sure I "need" to win the latest contest because I "need" a Longevity Plasma cutter. Feel free to translate "need" to "really really want" because they are cool and it would look pretty sitting next to my Migweld 140.

[scooba]

With that translation i think we all "need"to win the contest

[JustinWC]

Ok, I am pretty sure I "need" to win the latest contest because I "need" a Longevity Plasma cutter. Feel free to translate "need" to "really really want" because they are cool and it would look pretty sitting next to my Migweld 140.

Don't we all... I need an 80 amp plasma for my new cnc table.

[J33PMan]

Starting on my swing out tire carrier for my Jeep.



Feeling better about the welds

[JustinWC]

I was looking at the last weld. Nice Job! Here is a tip to make it a little better. I had to learn it the hard way.

It looks a little too flat. I do those types of welds all the time. One thing you might want to do is make sure you tie in the horizontal tube's rounded corner a bit more. The rounded part takes a bit longer to melt (since it is more metal mass) than the vertical tube. I "aim" most of the heat into the rounded corner and it bleeds over to the cut tube easily without burning through. If you were to aim the wire at the middle of the two pieces at the correct heat setting you would likely burn through or have to move faster than would allow a good penetrating weld to occur. Aim more for the rounded part of the horizontal tube and slow down a bit and you will produce a better weld. I have marked up your weld with lines. Aim for the green line not the red one.
I personally put a small angle (maybe 10 degrees) in my mig gun to aim into the rounded corner. I never worry about overlapping the other tube. It ALWAYS fuses. And I never burn through. I can even run hotter and never burn through because that rounded corner sucks up all the heat.

[J33PMan]

Right on, thank you for the advice. I will work on that. I must admit to having to fill a bit more gap than I intended to fill. The fitment was not as tight as I would have liked. If I were to lay a second pass, would I still focus on the green line?

Thanks again.

[JustinWC]

Right on, thank you for the advice. I will work on that. I must admit to having to fill a bit more gap than I intended to fill. The fitment was not as tight as I would have liked. If I were to lay a second pass, would I still focus on the green line?

Thanks again.

For a second pass I just hit the middle of the joint (Red line).
I admit I have less than ideal fit ups too sometimes. But anytime you are welding tube in that orientation the rounded corner automatically makes for a bigger gap even on a good fit.
For poor fits, simply aim for the green line as you normally would but use a spot time method. Think "overlapping tack welds". If the gap is big reduce the angle on your gun a bit closer to 90 degrees. Each tack should be about one full Mississippi count or slightly longer depending on thickness. (I do a lot of 14 ga and use a slightly short count). So to do that, I tack each corner, then alternating corners, overlap tack welds by about 1/3 until you reach the middle. (BTW there is a reason to start at the corners so do it exactly as described) When you get near the middle you have to let the area cool a few seconds before the next tack. And it usually produces a weld that looks just like the one you made. I let it cool for a couple minutes then place a nice bead over it, down the middle of the joint.

Also the method I described works well to repair where you have burned through and made a nice key hole. I never turn down my welder below the specified setting for the metal thickness I am welding. That is simply asking for poor fusion.

I hope that helps.

[JustinWC]

Here is how I would do my second pass over the weld you have there. You want to tie in the edge of the first weld with the full of the rounded corner.