Re: welding tips

["Mark Battley" <m.battley@domain.elided>]

Mark Denovich gave an excellent overview of welding gear and techniques.

I'd only add a few comments, from my occasional experiences as a DIY bodgy
welder:

Yes go for 0.6mm (.024") wire, rather than the 0.8 that typically comes
standard with most welders. The 0.8 is okay for heavier gauge (1.2-1.5 mm
sheet) as in some of the more structural under-structure (antiroll bar
mounts, inner guards etc), but requires too much heat for thinner exterior
panels.

Get some (at least three) magnetic clamps - these are strong magnets, often
in triangular shapes, which are invaluable for holding panel and patch edges
flat and together (particularly in the centre of panels), or at 45 or 90
degrees. They only cost a few dollars.

Scrounge as much scrap steel as you can to practice on, and expect to spend
a lot more time practicing than actually welding on the car. Most of the
time on the car will be prep and finishing work anyhow.

I don't have an auto-darkening welding helmet, wish I did, probably should
get one. 

Best tool on the angle grinder I've found is a sanding wheel - a rubber disk
which takes round sheets of coarse (I typically use 36-80 grit) sandpaper.
Removes metal nearly as quickly as a grinding wheel, but because it is
compliant it tends to take more off the high spots than the surrounding
metal, and doesn't make as big nasty grooves when you slip....

Get some old wool blankets to protect other parts of the car from stray
sparks and grinding debris. Beware of cotton painting drop sheets, they burn
too well.... AMHIK.

If you are butt welding it makes it heaps easier if you can clamp a backing
plate behind the joint while you weld. Mark's copper suggestion is great,
I've also used aluminium.

Once word gets around, beware of neighbours bearing broken garden furniture
who want to waste your car-time!

Have fun..

Mark.

Mark Battley
Auckland, New Zealand.

1973 Alfa Romeo 2000 GT Veloce (some done, lots more to do...)
1989 Fiat Uno Turbo (0.8mm panels, fun, fun, fun...)
1989 Fiat Croma
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