Flux-Core on a Kennedy 520?

[larryq]

I've got a Kennedy 520 toolbox the previous owner didn't exactly take care of. There are some seam splits along the bottom edge caused by rust. About half an inch on each side in total, in small sections.

I've stripped the box and wirebrushed the rust. However, I have a Lincoln HD140 that I'm trying to use in flux-core mode on the lowest voltage setting and it ain't working. It's burning pinholes in the metal.

I'm always ready to blame this on my pi** poor welding skills, but do I need to go MIG for metal this thin? And, is it possible to do what some of the autoshops do now and glue a new piece of sheetmetal on there with (say) JB weld or whatever they use, and grind the seams as best as possible?

This obviously will never be a mint resto, but I have to hand it to Kennedy. Even with all the abuse this box took the slide rails are arrow straight and the drawers open and close like new. Thanks guys.

 

[JimDon]

Got a buddy with a TIG and is skilled with its use? Take it to him. He can do it on low low settings without warpage. Flux core is going to f it up with burn thru. If you've got a torch set up, braze it.
Jim

 

[crewchief888]

gas weld it.

welded up service truck boxes many times with a torch and a coat hanger

 

[8paintchips]

You have a lot of cards stacked againts you here, one flux core is poor for welding sheet metal (thin metal). Two the rust will cause pin holes, and blow outs, and is almost imposible to get rust completly out of metal that thin.

YOu may need to cut out the rusted sections and weld in new home made patch panels, resarch auto body welding for the correct technique (tons of info on the web about this). Dont try to weld a bead just make lots of little tacks.

Or if you dont give a dam how the box looks and you just want to use it, I'd just put rust coverter on the rusty spots paint them, cut some thin angle iron to reinforce the split edges and tack weld or rivet them on there.

Oh heres a pick of a pannel I made and mig welded on my truck this should give you the right idea.

 

[larryq]

Thanks everyone. Some excellent suggestions here.

You have a lot of cards stacked againts you here, one flux core is poor for welding sheet metal (thin metal). Two the rust will cause pin holes, and blow outs, and is almost imposible to get rust completly out of metal that thin.

YOu may need to cut out the rusted sections and weld in new home made patch panels, resarch auto body welding for the correct technique (tons of info on the web about this). Dont try to weld a bead just make lots of little tacks.

Or if you dont give a dam how the box looks and you just want to use it, I'd just put rust coverter on the rusty spots paint them, cut some thin angle iron to reinforce the split edges and tack weld or rivet them on there.

Oh heres a pick of a pannel I made and mig welded on my truck this should give you the right idea.

 

[el tanque prohibido]

Flux-core is too hot for sheet metal. Go with pulsed MIG or TIG.