Go back to home

Welding Info please

Author
P S Robbo
Enthusiast
  • Total Posts : 85
  • Scores: 0
  • Reward points: 3083
  • Joined: 2017/02/13 19:16:01
  • Location: Sydney
  • Status: offline
2025/05/09 21:30:41 (permalink)
0

Welding Info please

Hi all. I have a new project that requires a fair bit of welding and rust repairs. On You Tube it all looks so easy! I'm just after info on what everyone is using etc regards welding repairs, equipment, settings etc.  I'm using 1mm steel and butt welding with gasless. Using Mig. Have used all size wires but now use .6 flux core wire on the lowest welder settings. Still having trouble burning holes in the joins etc. Am I using the right size wire? Should I be using gas rather than gasless? Would like to know what all you experts are using etc. Thanking you Paul.
post edited by P S Robbo - 2025/05/09 21:45:21
#1


6 Replies Related Threads

    martymexico
    Deity
    • Total Posts : 2376
    • Scores: 256
    • Reward points: 5771
    • Joined: 2011/08/01 11:02:49
    • Location: Adelaide Sth Aust Australia
    • Status: offline
    Re: Welding Info please 2025/05/10 00:40:06 (permalink)
    0
    Hi, you can use gasless wire and. 6 is correct for thin metal, might want to speed up the wire but leave the current low . Gasless should sound like a constant fizz with crackles, similar to stick welding. I personally don't use dry weld unless my gas bottle has run out, I have 2x welders so I don't need to swap stuff out etc.
    To fill a hole you need to zap the metal in very short bursts adding the perimeter and then longer zaps to bridge it till it's all covered, or if you can use a backing like copper or brass block to help out. Best is gas welding but Deano will argue that! Has helped cool the panel and eliminate porosity And the end weld looks so much better with way less splatter. Use the same size wire 0.6mm but for gas, not flux cored. If you haven't a bottle or regulator just stay with gasless as the cost to swap to gas is in the $100s
    #2
    P S Robbo
    Enthusiast
    • Total Posts : 85
    • Scores: 0
    • Reward points: 3083
    • Joined: 2017/02/13 19:16:01
    • Location: Sydney
    • Status: offline
    Re: Welding Info please 2025/05/10 17:02:32 (permalink)
    0
    Thanks for that Marty. Just the info I was after. much appreciated.
    #3

    escortinadriver
    Deity
    • Total Posts : 1264
    • Scores: 111
    • Reward points: 6024
    • Joined: 2011/08/01 11:02:49
    • Location: Vic Australia
    • Status: offline
    Re: Welding Info please 2025/05/10 20:03:05 (permalink)
    0
    Completely echo all of what marty has said.... plenty of helpful youtube videos out there. practice practice practice. Mig will work best with CLEAN metal. Heat sink behind if poaaible will help no end. Can also help to get your welding settings setup in some scrap before moving to the same size panel.

    'If I'd asked what people had wanted, they'd have said faster horses....' Henry Ford
    #4
    P S Robbo
    Enthusiast
    • Total Posts : 85
    • Scores: 0
    • Reward points: 3083
    • Joined: 2017/02/13 19:16:01
    • Location: Sydney
    • Status: offline
    Re: Welding Info please 2025/05/11 16:55:08 (permalink)
    0
    Thanks guys
    #5
    MarkA
    Deity
    • Total Posts : 150
    • Scores: 72
    • Reward points: 1008
    • Joined: 2022/11/26 09:07:52
    • Status: offline
    Re: Welding Info please 2025/05/11 20:23:53 (permalink)
    0
    Sorry to add my two bobs worth but once you go over to gas you will never go back. And as Marty says, brass (or any non ferrous) backing is great if you have access.
    #6

    deano
    Deity
    • Total Posts : 1455
    • Scores: 293
    • Reward points: 3554
    • Joined: 2015/08/19 10:49:10
    • Status: offline
    Re: Welding Info please 2025/05/12 13:29:53 (permalink)
    +2 (2)
    ok, yes I have to chime in if its not too late!
     
    As a beginner too, I started with gasless flux core wire, much like yourself.
    And to be honest, I've actually only used gas once, doing some volunteer welding to get my practice up, so in reality, I probably dont know any better.:) 
     
    Don't forget, your wire isnt solid as it has flux in the core obviously, so ideally i'd suggest you'd have more chance with 0.8mm flux core, which is what i've used all along. 
     
    Some things I wish I knew at the start:-
    - gasless really splatters, so as said above make sure everythings clean, and spray it with anti splatter to make it easier to clean the beads off after. 
    - protect your ears: I got a hot bead splatter down the ear hole when welding an exhaust upside down, its still not 100% and hurt more than down the socks.
    - the easiest way to join a panel or patch is if you can make it oversize, and joggle an edge. Then you can drill holes in the 'main' part of the job and simply fill/plug  up the spots with your thicker metal, not the body. It's probably not 100% the expert way to go as you have double seams, but I think with seam sealer, it will outlast me and is safer than it was. Plus you can tack around the edges if you want also. Thats essentially how I welded bubble arches on.
    - watch Fitzy on YT for his way of tacking patches and trimming them with a grinder as you go (or my build thread on the van). It helps misimise distortion and is quicker than trying to get a complex patch to she correctly. I did van windows this way.
    - your repair patches at 1mm is going to be thicker than prob 90% of your panels, especially where they were stamped. And if its an Escort, that even thinner i reckon. So start any weld favouring the patch, putting less heat into the car if you can. If you blow through it will be from the bodywork, not the patch mostly.
    - A really good tip I got from one of the members, was to angle the torch back, this helped my technique a great deal.
    - I wipe down with wax and grease before welding, but dont leave your rag nearby like I did.
     
    And post up whatever you are doing. There are some very helpful people who can weld way better than myself who have tought me alot.
    A boilermaker told me, the best way to learn is to burn wire.
    #7
    Jump to:
    © 2025 APG vNext Trial Version 5.1