beginner welding projects

[markvfr]

I got a MIG welder this year as I always wanted to learn and after running some beads on coupons I thought I can still practice my technique while doing some small simple projects. Main purpose of this thread is to share some newbie projects.

First thing I wanted to make were some hangers on the wall for steel stock. Got some square tubing and 1/4" flat bar, settled on 30deg angle. Welded it up, drilled holes for mounting and tremclad rattle canned it. Welds were not pretty but strong. I cut some practice beads and etched them and the nugget had good penetration.

 

[markvfr]

After I graciously got some scrap metal from another member on this forum, I used some of it to make a small stand for my shock vacuum setup. It took me about 20 mins to make this. Some square tubing scrap and 5x5" square plate. My welds looked better on this piece, but I don't have any pre-paint pics.

 

[markvfr]

I got some reclaimed oak coffee tables for free so decided to re-purpose the tops and make steel frames for them. Got some angle iron, 1" and 2" tubing. Since I had an abrasive chop saw, cutting those 45deg angles was a bit of a pain, so next time, I'll notch the angle for the mitred corners.

During welding I had some issues with running too hot and burned some holes in the square tubing, so learned how to fill it and grind, grind, grind. Now have motivation to make nice welds as grinding *****.

Once the frames were welded up and painted, it was time to refinish the oak tops. After sanding 25 years of **** off of them, filled the cracks with wood filler, stained with a light walnut stain and finished it with Waterlox tung oil.

 

[markvfr]

I was getting fed up with only having the chop saw and not being able cut small intricate pieces and also being able to use it in my garage and not outside with all the cutting dust that the chop saw produces. I settled on a Milwaukee portable band saw. I got it this past weekend and decided to build a vertical stand for it. I got the design from "The Fab Forums" on youtube as it appeared to be the easiest design. Thanks dude.

Still had some 1/4" flat bar left over, some angle iron and cut some small tabs from smaller stock for the retaining tabs. I welded the base first, then fitted the angle iron to the saw. Then used some heat on the small pieces and the cross brace to bend it into shape and welded it last. My MIG technique is getting better and I'm happy with the results overall. The stand is perfectly stable, simple and portable.

 

[markvfr]

I hope a few of my projects I've shown can kickstart this thread to share some ideas.

On another note, I have also been practicing TIG, and man thats a whole different kettle of fish. MIG is a joke compared to TIG for me.

 

[buildyourown]

Those actually look pretty good. I'm a huge fan of making stuff as practice. I've got a few things in my shop that I gas welded 20yrs ago and are so ugly it is literally embarrassing. My day job is about 20% tig so needless to say, I've improved.
But you know, all those old ugly things are still working great and remind you were you started.

 

[markvfr]

Those actually look pretty good. I'm a huge fan of making stuff as practice. I've got a few things in my shop that I gas welded 20yrs ago and are so ugly it is literally embarrassing. My day job is about 20% tig so needless to say, I've improved.
But you know, all those old ugly things are still working great and remind you were you started.

I dunno, they all look like **** to me except for some of the beads on the saw stand. Thats how you learn though right?

Yup, I still have woodworking projects I made in grade 8 almost 30 years ago, man they are ugly.

 

[gayler]

I would post up some of mine, but my welds look like boogers and chicken poop.

 

[markvfr]

I would post up some of mine, but my welds look like boogers and chicken poop.

Please do. That's why I started this thread, to share ideas, not be crucified by welding pros on our less than perfect welds. Unless you ask for it of course. Everyone started somewhere and no one was putting down perfect beads the first time they picked up a torch.

 

[Crusarius]

All good welders are good grinders

 

[Piper27]

All good welders are good grinders

 

[SteveH-CO]

Remember the quote I saw here or somewhere else: 'a grinder and paint will make you the welder you ain't'

 

[2oolhound]

My feelings on it is you need to burn rods or wire. No amount of reading, advice or youtube videos will make you a welder. You need to do it. Pour your time into it. It also helps if you're driven.

 

[sberry]

Those do look decent. No one wonders wtf. I really sand that kind of thing more than grind and do it so slightly you usually don't notice its been done but to clean the splatter. I usually use a 1/4 wheel and bump the trigger a little and can really not leave grind marks.
I havnt really used flaps, I have sander with 36 grit on it too.

 

[Crusarius]

I love flap disks but they just don't last and are pricey. I usually just use a soft pad. Can get them in 36, 80, and 120 grit. Cheaper and lost a lot longer. Also being flexible makes them more versatile.

The best thing about flapdisks is once they wear out they make great buffing pads. Will leave a mirror finish on some materials.

 

[markvfr]

I love flap disks but they just don't last and are pricey. I usually just use a soft pad. Can get them in 36, 80, and 120 grit. Cheaper and lost a lot longer. Also being flexible makes them more versatile.

The best thing about flapdisks is once they wear out they make great buffing pads. Will leave a mirror finish on some materials.

I was hoping there was an alternative to flap discs as they are expensive. Can you guide me to some good softpads? Thanks.

 

[Crusarius]

This is the best I can do right now since everything is blocked at work. I guess it is called a sanding disk backer.

http://thumbs2.ebaystatic.com/d/l225/m/m7fuaWc-UfbXKykpIT990Gg.jpg

https://goo.gl/images/WwAFAE

 

[Crusarius]

I have accidentally ended up hooking the edge of the plastic back on sharp corners of sheet metal. It does make is smaller But the good thing about that is if you want to grind a tight radius you can shape the plastic to what you need.

 

[TauntDevil]

These look great. My first projects with my mig was stitch welding cars haha. They came out horrible but the people letting me didnt care, as long as it held xD

 

[michaelf]

All good welders are good grinders

sure is true, proper grinding is an art as is welding.

 

[sberry]

I am careful with the grinder to start with and try to cover my tracks. Where it gets a nice finish sand out grinding marks prior to blast or further sanding. I hate the splatter and the little places it lands and it takes just a whiz with a heavy sander to clean it off smooth. Yes, above, the backing plates and the disks. I have a 7 inch which is my fave and a 5 so a guy can gut the old disks down with old snips and use on it occasionally.

 

[gayler]

Please do. That's why I started this thread, to share ideas, not be crucified by welding pros on our less than perfect welds. Unless you ask for it of course. Everyone started somewhere and no one was putting down perfect beads the first time they picked up a torch.

How's this look? Using a harbor freight 170 welder with .030 flux core wire.

 

[moodubs]

hey fella keep up the good work, I have been welding professionally since 1983, we are all born learning everything we do, every day we learn more, no one knows everything (although there are some who seem to know more than google) keep at it

 

[markvfr]

Well, been running some coupon Tig beads on steel and aluminum. Good and tricky but slowly making progress. Now to build something with these beginner tig skills.

 

[bmxdad]

How's this look? Using a harbor freight 170 welder with .030 flux core wire.

Did you grind/clean the weld area?

 

[sanddan]

I have projects in my shop that I welded over 20 years ago. Most of the early welds were too cold but still keep it "stuck together" even today.

I agree that doing projects is the best way to learn, keep it up.

Good projects to do...

shelf brackets, can make them out of 1" sq tubing or angle iron.

benches and/or tables, I have 3 or 4 made out of 1", 1.5" and 2" square tubing. all are .120" wall thickness which is easy to weld. You can get 24"x48"x3/4" melamine pre cut at Home Depot for tops and shelves.

Stands for tools such as grinders and belt sanders. 3" or even better 4" square tubing and a truck wheel for a base. Most of mine have a base made out of 2" thick rounds that are drops from cutting larger sheets of steel. 14" to 18" diameter work good.

 

[gayler]

Did you grind/clean the weld area?

I cleaned it before welding. It is flux core welded and I just lightly wire brushed after welding. It still has some tanish **** on it from the flux.

 

[sberry]

That isn't bad. looks like it will work.

 

[markvfr]

Sanddan, great, thanks for those ideas. My progression is exactly like you said, brackets, tables and stands.

I'm now working on aluminum fishing rod rack which will be my first aluminum project.

I'm thinking of anodizing the final rack but can't find any rough cost estimates without calling a shop. Any ideas? The rack will be 24" wide and 6" tall.

 

[duwem]

First thing I did when I got my tig welder is build a welding cart for it.

 

[2oolhound]

My small shop is very crowded. I have about a ton of steel piled on my mezzanine floor so I beefed up the supports with two - 2" schedule 40 pipes that run floor to ceiling. I figured I could keep my mig up near ceiling height by building an arm off one of these vertical pipes.

I ended up making this articulating arm. There are no bearings, just 2" OD pipe inside 2 1/6th ID pipe. Each arm extends about 8" and there are 3 swivels, one at the vertical support pipe, then where the 2 arms join and the third is on the table the mig sits on. I wrapped a sheet of .oio" brass shim around each pivot to act as a babbitt bearing. There is very little free play.




It will extend to 6' long so it covers an area of 12' although it mostly will be used right where it is. I sat on it at full extension (240 lbs.) to test my welds

 

[bandaidmd]

How's this look? Using a harbor freight 170 welder with .030 flux core wire.

clean your metal before welding, you might lay down your best bead ever but that crud will float into the puddle and screw it up.

 

[beakie]

My small shop is very crowded. I have about a ton of steel piled on my mezzanine floor so I beefed up the supports with two - 2" schedule 40 pipes that run floor to ceiling. I figured I could keep my mig up near ceiling height by building an arm off one of these vertical pipes.

I ended up making this articulating arm. There are no bearings, just 2" OD pipe inside 2 1/6th ID pipe. Each arm extends about 8" and there are 3 swivels, one at the vertical support pipe, then where the 2 arms join and the third is on the table the mig sits on. I wrapped a sheet of .oio" brass shim around each pivot to act as a babbitt bearing. There is very little free play.




It will extend to 6' long so it covers an area of 12' although it mostly will be used right where it is. I sat on it at full extension (240 lbs.) to test my welds

that's a pretty neat idea, one I may borrow down the road.
I would maybe go 12-18" per arm.

only addition I would make is it riding on a vertical tube with through holes every 1'.
so I can use it low, or raise up high if working on otherside of a vehicle/trailer/etc.


good job

 

[littleviking]

I cleaned it before welding. It is flux core welded and I just lightly wire brushed after welding. It still has some tanish **** on it from the flux.

I know people say Flux Core is farm welding and usually doesnt need to be cleaned and de greased before welding. Mostly they are saying that because it WILL weld through rust and dirt and grime.

However, If you take a few minutes to grind down to bare shiney metal and then brush that off and keep the weld area clean your weld will improve drasticly not only in apperance but in strength.

That weld looks to be fully engaged and I don't see anything that makes me think its a bad weld.

next time just hit it with a flap disc till its shiney and give it a good bead.

Otherwise looks good to me.

Then again Im a fluxcore farm welder. :-D

 

[gayler]

I know people say Flux Core is farm welding and usually doesnt need to be cleaned and de greased before welding. Mostly they are saying that because it WILL weld through rust and dirt and grime.

However, If you take a few minutes to grind down to bare shiney metal and then brush that off and keep the weld area clean your weld will improve drasticly not only in apperance but in strength.

That weld looks to be fully engaged and I don't see anything that makes me think its a bad weld.

next time just hit it with a flap disc till its shiney and give it a good bead.

Otherwise looks good to me.

Then again Im a fluxcore farm welder. :-D

Thanks!

 

[2oolhound]

Thanks for the compliment beakie.

I got the idea from this drill rotisserie arm I got with my drill press when I bought it. It works so well I figured I should copy the concept.

 

[Mr_fixit]

I would post up some of mine, but my welds look like boogers and chicken poop.

Some of my good friends weld that way.