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Learning to WELD!

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bczygan

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GOT IT!!!

The tungsten grinder!

It is a Black and Decker rotary tool with a Techsouth attached grinder.

s-l640.jpg


http://www.techsouthinc.com/grinders/manual.html"]http://www.techsouthinc.com/grinders/manual.html[/URL]

_MG_0542.jpg


Works good.

Bill
 
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bczygan

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OK, welding cart...

Why do a lot of carts place the welder at an angle? Is it because they are low and this makes it easier to see the controls? And are they low to keep the center of gravity low?

My cylinders are the 330CF T size, so very heavy and very tall. The welder (AHP Alpha TIG) is also tall, and has a plastic shield over the controls that flips up. This makes them hard to get at it it is low to the ground.

Needs to roll well outside over driveway cracks, so larger wheels without adding too much height.

Thinking about adding plasma to it or MIG.

Needs racks for cables, foot amptrol and drawers for consumables. Also storage for filler rod and electrodes.

How about a plug for the tungsten grinder?

So heavy duty, but don't want it too heavy, so what gauge of metal? What structure?


Bill
 
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bimmer1980

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Spend some time browsing the various weld carts that have been fab'd and posted on this site...

There are many and a variety of designs...

Build one that works for you...

1x2 steel tubing or 2" angle is more than sufficient...

I would probably go with 8" or larger rear tires by the tank and 3" or larger caster wheels for the front.

Not a bit fan of pneumatic tires as they give too much and the tank can get unsteady... At least, the HF tires ****...

Some years ago, I built a small weld cart that had a small welding table above the welder. The weld table was only about 12" x 18", but it worked good for the century 110 welder with tank. I used 1" square tube for most of that build.

As with any project, tack it together, test fit everything before welding completely.

Since you have limited space. Keep the project tight, compact and functional. Don't make it into an insurmountable project that won't get done...

I would try to build in a rack for C-clamps, hoses, cords, Tig torch holder etc.

Again, it doesn't have to be perfect, just functional....

Have fun...
 

LXCam

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Well you're coming right along Bill, congrats on gaming some headway on the new skill set.
 

ez-duzit

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...Why do a lot of carts place the welder at an angle? Is it because they are low and this makes it easier to see the controls? And are they low to keep the center of gravity low?...what gauge of metal? What structure?...

More important than welding skills are design and common sense skills, if you're going to build useful stuff for yourself and others. Do your own due diligence on researching various design approaches and try to understand why the successful projects turned out as well as they did, and why unsuccessful ones failed.
 

sberry

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Not me. I have 1000's of hours behind a good especially early in my career. I got to push myself or take a little opportunity to keep in shape and it takes work to be disciplined. I stick welder a customer job I wish i would have got pic of the other day, did it all vertical and it took me a couple rods to focus and was actually getting better after a few.
It takes me 10 days or couple weeks a few rods a day before I am really driving the machine. I weld a little but it's mostly a rod or couple inches here and there and would be in real trouble if I had to pass a critical test.
I wouldn't have much trouble on simple ones but a picky fugger like a nuke I would be sweating my way thru it.
 
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bczygan

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Ran a few beads yesterday. Steel and aluminum. Tried to get some stacked dimes using pulse settings. Will try pulsing with the pedal, when I get a better one.

Gotta keep my hand in with regular practice.

Bill
 

trackwelder

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I'm hungry.

Not for food.

But for running a bead.

Anyone have that desire just come over them?

I'm going downstairs and stick some metal together!

Bill

Not at all. Only the desire that requires welding to finish a project.
 

sberry

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I been doing this since I was a squirt. A lot of people mistake my interest in mechanical as an interest in mechanical and it's really not.
All this is because there is something i want, want to get done, effects production, is a problem in the way and welding/mechanical is a solution or a way to make money.
When I live elsewhere, have a job I didn't have all the **** and it wasn't a hobby.
 

Bigblue&Goldie

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I'm hungry.

Not for food.

But for running a bead.

Anyone have that desire just come over them?

I'm going downstairs and stick some metal together!

Bill

I find pushing puddles relaxing. If I'm in need of some stress relief I'll bust out the Tig torch and make something small. I did iron work for a while out of college and loved it, but I haven't arc welded since then. I don't make money welding, but my ability to weld has got me further in motorsports and has saved me a ton of money over the years. We're currently putting together a new car for King of Hammers and I'm looking forward to a few nights in the garage listening to music and burning rod.
 
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bczygan

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I been doing this since I was a squirt. A lot of people mistake my interest in mechanical as an interest in mechanical and it's really not.
All this is because there is something i want, want to get done, effects production, is a problem in the way and welding/mechanical is a solution or a way to make money.
When I live elsewhere, have a job I didn't have all the **** and it wasn't a hobby.

I fully understand that for most people, skills like this, are for definite and practical purposes. And for many, the ultimate purpose is making money.

But some people have other reasons to take it up.

My welding class is an example. While most of the class members were interested in welding careers, 2 of the students wanted the skill for their artwork and 2 other students had no practical reason to learn. They just wanted to know how. I was one of them.

Bill
 
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bczygan

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A week from Friday, my first MIG class begins.

Looking forward to it!

Gotta get the 120V Lincoln MIG hooked up.

Looking for a 240V machine! Something in the close to 200A range.

Bill
 
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bczygan

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Living in the burbs and for hobby/maintenace its likely the only machine i would have.

I tried my MIG machine. Lincoln 3200HD.

039-4.jpg


Hooked it up and ran a few short beads with solid wire and gas. The steel plate was really too thick for that. Should have used flux-core. On the flat and beads were humped up a bit. Smooth and straight though. All that TIG work made this seem easier. I need to get some thinner stuff and try some T joints and such. And the chart on the machine got me right close to where I needed to be.

This little 135A 120V machine seems like it will be great for what it does, but I still want a bigger machine. This one won't use a spool gun but it is handy to be able to use it on 120V. Will likely keep it no matter what.

In school I'll be using a Miller multi-process machine.

xmt-350-cc-cv.jpg


Fun!

Bill
 

sberry

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That isnt the setting you used? Get a pic of the door chart. I got one and it isnt right, its missing a lot of the settings, not sure why.
 
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bczygan

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That isnt the setting you used? Get a pic of the door chart. I got one and it isnt right, its missing a lot of the settings, not sure why.

Good morning sberry!

That isn't my actual machine, just a photo from the net.

Steel was 1/8".

I was using D for the heat and 4.5 for the wire speed. Then I slowed the wire speed to 4.

Chart for my machine is attached. The dark blocks are places where no settings are available, so I was using the wrong settings for the metal thickness. Should have used flux-cored and D-3.

Bill
 

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sberry

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That machine will weld 1/8 easy with gas. The power on a feeder is the wire speed, you should have been at D7 and maybe E if the arc didn't become erratic. I weld most stuff with those at top end, even thinner stuff if I can. You don't HAVE to use the low settings, the hi is so much faster and in some sense easier as it requires less from the operator except to move, lets the machine do the penetration vs the guy wiggling and weaving to get it to melt.
 
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sberry

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Now find the top end and ignore the chart except when turning it down some to keep from burning thru or where you need control for gaps etc. When using small machines don't fit tight, leave a little gap and some edges to assist in melting. The machine will weld 10,,, or 1/8 quite weld and some limited thicker depending on joint design.
 
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bczygan

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Now find the top end and ignore the chart except when turning it down some to keep from burning thru or where you need control for gaps etc. When using small machines don't fit tight, leave a little gap and some edges to assist in melting. The machine will weld 10,,, or 1/8 quite weld and some limited thicker depending on joint design.

Sberry,

Thanks!

I took your advice and turned speed up to 5 plus and heat on D (Which is highest setting).

Ran a little T joint with e shaped manipulation. It was really my first real MIG joint.

Turn out good?

Bill
 

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sberry

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That is good,,,, but,,,, again, the "heat" or amperage is the wire speed on a feeder. The voltage is arc intensity or arc length. Turning it up only has a little effect on the actual wattage.
Yes, the weld is good, you can try little different things, I rarely weave, a little wiggle sometimes but try to have it hot enough that it flows on its own and can get the arc leading the pool right in the groove of the joint.
Out of all the **** you have this should really be the main machine and be your workhorse. A 240v 180/200 class is almost 2x the machine and 030 gives it some capacity to weld thicker faster but in your case if you are doing any real work so much in todays world is sheet metal and some close to foil, that machine with small wire is a lot easier.
I didn't realize it went only D, I have a Pro Mig and it has a 5 speed.
Don't be scared, turn the speed up some till it stumbles, that's all the power its got, turn it back down till its smooth. It shows D 7 as wide open. If it will arc right on 7 will have a lot more power than 5
 
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bczygan

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I actually measured, and the first piece of steel and it was 3/16".

The one with the T joint was 1/8".

So yes, it welds 1/8 quite nicely!

Now I need to try thinner materials and explore it's range.

But since I don't have thinner materials, I'm going to try a 3/16" T joint.

Bill
 
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bczygan

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Got my clear glass #8 Furick cup and gas lens today.

Put it on the TIG torch, but haven't tried it out yet.

Bill

Tried it out.

Thought the cup might give me a better view of the puddle, being glass.

But as some others mentioned, it really didn't.

Still glad I got the gas lens. It should help with gas coverage.

And I like the angle tipped collet too.

Bill
 
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bczygan

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Signed up for another welding class.

This is in addition to the MIG class that starts Friday.

It is a more advanced stick class and starts tomorrow.

I had the time available, and just want to take advantage of the opportunity.

In addition, there is a fabrication class I can attend, for extra practice time if I like.

Bill
 
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joe49

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Coming from Chicago, I learned security of my stuff depended mostly on stealth. I mean not allowing it to be seen. My point is welding gives it self away with the intense light. Just something to think about.
 
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bczygan

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Coming from Chicago, I learned security of my stuff depended mostly on stealth. I mean not allowing it to be seen. My point is welding gives it self away with the intense light. Just something to think about.

Good point!

My two closest neighbors, and best friends in the neighborhood, know what I have, but no one else.

I work with the door closed. Should cover the one window, even though you can't see it from the street.

Everything is bolted closed. And I have a dog and a rabid wife for protection. Both have very sharp teeth and attitude.

Bill
 

joe49

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Come evening even the smallest openings will have very noticeable light shows. Most seeing will know welding is going on. Equaling tools. Hide your light.
 
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bczygan

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The starting date for the welding classes was Wednesday, but frigid temperatures caused the school to be closed through today.

So my first welding class is tomorrow at 3PM.

It's been a long wait for a semester that was supposed to have started on the 14th!

Bill
 
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bczygan

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Finally!!!

.............A welding class to go to!

Half was lecture and then had to quit because ventilation wasn't working.

At least I got a little seat time. Using a Miller XMT 350.

A couple of MIG passes.

Bill
 

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BajaScout

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Just wanted to let any veterans out there know that Workshop For Warriors in San Diego offers free welding training (and other training) and certification for veterans and active duty. They also assist with finding employment.

https://wfw.org
 

Lassen Forge

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Go to the local junk store or even spend some $$ on some 1/4 or 3/8 steel.

And start playing. Welding is a fun pastime that pays off.

IIRC you have a press, and that's how you can tell if your welds have penetration and aren't cold or hot... Our benchmark in school was starting at 15 tons, and you had to double that or better to pass. And when you know how, that's easier than typing here....

Another hint - if it sounds like frying eggs, you got the arc right.

But yeah, the key now is to practice, practice, practice. Run beads, start doing fillets, doing 90's, damn. This is a skill you'll use for the rest of your days. At least now they have auto-dark helmets (I learned with a 2x8 screen - and a solid flip down helmet - them bad ol days)... make sure you have good gloves (more when you pick up that 1100 degree hunk of steel and forget it's 1100 degrees) and keep you from getting flashburn... and at least a thick cotton leather long sleeve shirt if not welding leathers. (Yes, they're kinda worth it).

Your gloves and leathers (or shirt) are all expendable (not immediately, but I've replaced gloves some once a year, leather welders jackets about 3-4 times) but the real key is practice, practice, practice. Take a class at the local community college, watch youtubes about beginning welding, learn what a good weld VS bad weld is...

And go to town. Because it's like magic - taking something no mortal man can bend, and joining pieces of them together like you are Thor and his hammer, and learning how to make it stand up to 35 tons or more of stress - so you can build awesome goodies.
 
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