Welding help needed....Thanks!!!

bigjoe · Last edited by bigjoe on Tue May 11 10 8:14 am; edited 1 time in total

I dunno if I have the wrong type welder or what....

There are gaps (up to about 1/4" Embarassed

) between the transfer pipes and the firebox. Walls of both are 1/4" thick. I'm having trouble filling the gaps. I tried running a bead upon bead, but looking like hell and using a lot of wire. Used up my shielded wire and went out and bought a spool of both kinds, flux core and shielded. Flux core just spattered everywhere, no matter the amps. The shielded just doesn't want to build a bead. Had no trouble getting a bead where the metals touching, just where the gaps are. I have a Lincoln Electric 135 Plus MIG welder...will that work or do I need a stick welder? I'm even thinking of trying to Braze it, would that be ok instead of welding? My welding (non)skills SUCK!!! Embarassed

Wanted to do this all by myself....may end up calling a buddy... Embarassed

Jim_K · BBQ Fan Joined: 26 Dec 2008 Posts: 244 Location: SW Va

Joe Dont forget to set up for DC Negative to weld with Flux core! It will look like crap if you dont. Wink

wish I was closer I would help ya.

pyronoel · Posted: Sat May 08 10 8:39 am Post subject:

Find a spool of solid core steel wire that will fit in your gap, then weld that into place, really helps to span a gap. Sounds like you don't have the amps to build a pool to span the gap. --too hot will just drip, it's a fine line.

I've had a lot of gaps to fill, and having some wire to shove in the hole makes a big difference.

k.a.m. · Posted: Sat May 08 10 8:46 am Post subject:

bigjoe, I do not weld with a wire feed but I believe I can help. There are two ways to approach that size of a gap. The first is to weld bead after bead on each side of the gap to build towards the middle. But you need to clean up between each pass or you will get porosity in your welds. The other way is to lay some filler metal strips in the gaps so you can lace across and tie the two together. This is how I would approach a gap that size if it arose.
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bigjoe · Posted: Sat May 08 10 10:13 am Post subject:

THANKS!!

I have some 1/8" cold roll, didn't even think of using it to fill the gaps. Rolling Eyes

Sure glad for the knowledge here.

I'll try it if the rain holds off tomorrow, right now we're in a Tornado Watch...lightnin like all get-out. Shocked

Was sorta hopin to get a lil smoke goin this weekend to see what's what. Sad

Jeff T · Posted: Sat May 08 10 10:58 am Post subject:

Another thing Joe....once you get er filled up, a hand held grinder can make the sloppiest of welds look pretty dang good. Wink

Most times i cant weld worth a tinkers dam but i sure can use a grinder. Very Happy

mrcustomsteel · Posted: Sat May 08 10 11:21 am Post subject:

Joe, you are right on with the 1/8" rod, like k.a.m. suggested. Weld it to the end of the gap then bend it and tack it every inch or so. Once you get to the other end, weld it and break off the excess while it's still glowing orange. When you get the gap filled like that, go back and run your beads over it. Then grind it pretty like Jeff said. No one will ever know. It is tough filling big gaps with flux core, more penetration per amp per wire size.
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dannyjl30 · Joined: 19 Jan 2010 Posts: 6 Location: northern california

you could use hard wire like mentioned above e70s6 with co2 and run it downhill

Wreckless · Posted: Sat May 08 10 7:26 pm Post subject:

Same theory applies with my fix using 1/8" stick rod with the flux knocked off. I use the filler rod much like you would with oxy / acet or tig welding, adding the filler to the weld pool with the the welding source ( Mig gun or stick electrode) being the heat source in place of a torch.
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bigjoe · Posted: Sat May 08 10 8:49 pm Post subject:

Thanks all! Looks like the rain might hold off and I'll give it a shot today. Windy as hell, gonna have to use the flux core. I sure like the shielded w/ the gas better....lots less splatter and I can get a halfway decent bead....usually. Confused

killswitch505 · Posted: Sun May 09 10 1:13 pm Post subject:

doug · Posted: Mon May 10 10 6:48 am Post subject:

and don't forget to reverse your polarity (switch your cables around inside the welder) for your flux core wire!
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bigjoe · Posted: Mon May 10 10 7:07 am Post subject:

I reversed the polarity, after I tried it first...forgot. Embarassed

Spent the day with my wife n' kids for Mothers Day, gonna work on my welding skills tomorrow.

I'm gonna save up for a stick welder to go with the MIG...may be a while tho...this build is still costing me a lil' $$$ to finish it up.
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bigjoe · Posted: Tue May 11 10 8:13 am Post subject:

Thanks for the advice, guys! They ain't the prettiest, but they're done.

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killswitch505 · Posted: Tue May 11 10 9:00 am Post subject:

looks from my house Very Happy

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mtrammel · Posted: Wed May 12 10 1:51 am Post subject:

I am no expert welder and just figure out what works. I use a MIG as its all I have and its a 140 so I'm in a very similar boat. I have found when I'm filling a gap that running a quick second or two pulse...letting it stop glowing and pulse it again etc, I can bridge most all gaps. Then turn down the power and do a normal bead across the top. On a trailer or submarine...probably not the best technique...on a smoker gap of 1/4 inch....
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