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Welding observations that I have made....

In 2014, I did the frame connectors in the red car with the car on jack stands! This was really difficult not only to do it but to do it well.

IMG_4342.JPG


The seam where the connectors meet the floor pan isn't welded, that is seam sealer, I only welded at the ends where the connectors meet the frame rails and crossmember.

IMG_4343.JPG


IMG_4344.JPG


Everything was smoothed over with a grinder using a flapper disc.

In 2020, I had a lift and did frame connectors in another car...

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Being able to stand while welding sure did help but I still had a little trouble with the welds.
 
Overhead is for sure a challenge for me sometimes. It gets even more interesting when you put thick together with thin. Like the floors to the SFC's. I've found that when doing that stuff, don't try to run a long bead. Try to focus mostly on the thick with a little to the thin. I set my unit, Lincoln Power Mig 215, to around 18ga with a little dial adjustment on the wire speed. Lay down maybe 1/2" and move a foot away, then repeat. Heat travels up so it doesn't take long to get craters in the thin. Somedays I nail it good, others it looks like birds flew by. Greg, is your unit a 110v? Reason I ask is my first one was a Lincoln SP110. I was welding in the trunk floor on my Challenger and just could not get it to perform. Looked like bird poo with no penetration. Turned out the problem was I had the unit on the very end of the electrical run in my garage. I plugged it into an outlet in the house, where the power came from for the garage, and I was an instant pro. That may be something giving you issues with your unit to check out.
 
THE best stick weld I ever did was at 13’ on a semi-trailer door frame. Couldn’t get high enough to see down, so just watched the stick!! Lucky i guess. My frame connectors were done 40+ yrs ago,still going strong. My old boss that taught me was certified for Navy welding at Babcock &Wilcox. He also said, practice,practice etc.
It’s also easier w/o bifocal need & young eyeballs!
 
I didn't read every post here but with that said, practice practice practice like someone already said. My first time to strike up an arc was in 69 however, I've been learning ever since. Someone said learning how to stick weld is key and I believe that to be true. At my access, I have all 3 here but welded sheet metal using stick early on. My machine now goes down to 5 amps and everything in between up from that. I love it! You can even use a 225 cracker box to weld sheet metal if you run more lead to reduce the amps.....but you better run with a damp sponge with a hole in it to control the heat around the weld. Yeah, you weld into the hole lol
 
I started with an arc welder back in high school, had a cheapie flux core from tractor supply for several years borrowed a lincoln mig from a friend when I did my charger with his coaching back in '14. Bought an ESAB mig tig stick combo a few years ago. Had the problem seeing also, I purchased a cheater lense for my helmet (1.5) and always have a light shinning on the area. Cleaning the metal also helped, practice practice still learning
 
I set my unit, Lincoln Power Mig 215.

Greg, is your unit a 110v? Reason I ask is my first one was a Lincoln SP110. I was welding in the trunk floor on my Challenger and just could not get it to perform. Looked like bird poo with no penetration. Turned out the problem was I had the unit on the very end of the electrical run in my garage. I plugged it into an outlet in the house, where the power came from for the garage, and I was an instant pro. That may be something giving you issues with your unit to check out.

This one of mine is 220 volt. It is the Home Depot version of a Lincoln 175....they came with no provisions to run the gas setup. I had to buy a conversion kit. It has two simple dials, A-B-C-D-E for heat range and another knob for wire speed. It is basic and simple.
 
In my limited knowledge, Lincoln or Miller are the top of pyramid. The old Lincoln “buzz boxes” were simply the best out there.
 
In order to make a good weld you need to start with stick. Stick will teach you what you need to do. If you can't see what's going on in the puddle and how much you're cutting in you'll never catch on. I've worked with coworkers that could mig weld the most beautiful beads you ever seen. The problem was they hadn't penetrated very well. The backside of the weld didn't even show any discoloration and in a drop test, the weld would crack. Stick welding is a different technique from mig. It's more of a whipping in and out of the puddle. Takes practice but once you learn how to weld with stick your mig welding will improve.

Seeing what your doing is of upmost importance. Lots of auto darkening helmets have light adjustments from darker to lighter, depending on your eyes. Also if you wear prescription glasses you might want to try taking them off when using your helmet. Some people have to use a magnifying lense to see better. You have to figure out what works for you to be able to see a clear picture of what's going on in the puddle.
:thumbsup:
yep need to see the puddle to weld, anything

you can see, if you can't see well, that it won't be pretty
even for an experienced welder

my eyesight has gotten way worse, I blame that now
I have to have it dark behind me
(sometimes even a big piece of leather over the back of my head & helmet, to keep light out)
& I like it really light in front of me now,
or I have to wear glasses
(that magnifies the weld & the arc too, makes your eyes really tired
& hurt after, even with darker lenses)
even with my auto-tint/dark helmet, until you strike an arc, mig or tig
or gas welds even

I haven't stick welded much since I worked for PG&E in 1977 to 82-ish

yeah it's good to learn all aspects too

not many pros, stick 'arcweld' cars ever, it's too dirty,
too much spatter, everywhere & hot slag, or grinding (osculating C welds, patterns in & out)
very hard to weld thin stuff too
or let alone some chromoly or thin mild steel tubing, like on cars

my stapdad Bob tough me to gas/oxygen acetylene weld
2 steel cans (called tin cans, back then, but steel) together at like 10,
you need to see the puddle & move the torch accordingly...
I don't think I have that patients now, or the eyesight,
I had even 10 years ago...
And it's probably from welding so much in tight quarters, building 26 racecars
having to get your head in places where you couldn't fit a helmet
dark sunglasses even sometimes & getting way too many flashes,
screwed over my eyes (I know that why I have to wear reading glasses now)
from others arcs, working in Boilers at PG&E, stick welding stainless 7118 rod IIRC
I hated that dirty **** & the huge hunks of nasty *** slag
& constant grinding stops & starts, penetrates but not for cars,
maybe truck frames, even a good mig, with a larger shield on the torch
& use a 240 volt machine, pref. not a 110, unless it's just bracketry etc.
not on rear ends or suspension stuff
110 vt slow down & really watch it, puddle make sure it's getting penitration
(110vt machines you have to slow down the wire feed,
needs to sound like fry bacon in hot grease & use like 0.023" wire & tips
)
& with CO2/Argon mix CO2 helps it dig penetrate, on either style machine
& one with a good 'working duty cycle'
straight Argon is better inside a closed shop, not wind at all, no fans running etc.
but the CO2 mix is better, caveat is depending on what's being welded

There are a lot better options now for most the stuff any of US will weld

Most of us aren't building bridges or boiler makers,
welding much thicker than 1/4" (0.250) 3/8" max (0.375)
12ga - as thin as 20ga or maybe 0.080" to 0.120" wall mild steel tubing ****
(maybe chromoly once in a while on cages etc.)
or welding on posts or make "BBQs" or working on our cars or trucks yeah

I am no expert by any stretch, just a hobbyist,
former certified combination/pipe welder, when I was young & could see well
get in weird positions all over the place, working in the Bay Area powerplants...

good luck
 
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I adjust the amount that the lens darkens but it is the time before the weld begins where I have trouble seeing since the lens already shades a little before darkening. If I have nearby sunlight, I am fine. I'm even okay in shaded areas...it is after sundown wity only the overhead LED florescent bulbs in a 10 foot ceiling where the light isn't enough.
I didn't get a chance to weld after dark tonight...I got tied up talking with a guy in Vermont, then had to mow the lawn.
Maybe if I got off my *** and went outside before 1:00, I'd have more time....

01 face 1.jpg
 
Kern...I've found the timing and brightness of the screen to be crucial adjustments...

Too late with the timing you get a quick blast of bright and then its like your snow blind...

Too bright and it's kind of the same when your eyes react to it...

The biggest problem I've had lately is the shields fogging up between the lens's in the helmet...

I think it's from all the humidity from the heater but you have to have one to have the other...
 
Keeping the helmet lens clean is a big asset. I used to order new clear lenses by the 10 pack from the stores department, about every week or two I would take my helmet apart, clean the cassette (the auto-darkening lens and control pack), and put in new clear front and rear plastic. I always noticed the difference, even if I thought it was pretty clean before hand. It made the difference between seeing just the arc, and seeing the whole welding bench.
 
You'll get stick welding just keep practising. Stick definitely not ideal for bodywork but good to know. Just a few tips I hope are helpful: (Flat position,fillet weld,horizontal,overhead) Watch your puddle behind the rod, you want it to be a constant oval(egg) shape(oval egg shape also indicates your speed is in the right area), roughly 1.5x-2.5x the rod diamater(depending on what weld size you're going for). Keep a close arc length as your electrode gets shorter unlike mig. One of the most important things is getting comfortable, lean on a table, use your forearms/elbows whatever it takes to keep your hands/arms from shaking.
Been a journeyman welder since 2001 and i'm ready to do something else:lol:
 
I spent my life as a Carpenter but have been a car guy even longer. Quite awhile ago I learned that you really limit yourself if you have to rely on others for welding things.
Old cars with crash damage or rust will need repair. You can get on the list and wait your turn or find a way to do it yourself. There are numerous times that having a welder here has saved me money. For almost 30 years, I’ve only done MIG welding. Most automotive stuff can be done with the MIG. I’m not a great welder but I do okay. This past month I started a welding class with another FABO member. This week we did some stick welding, a type that in my opinion, is obsolete for what kind of stuff that I do. I took the class to improve my MIG skills but this class is geared to exposing students to all the common welding techniques. SMAW, GMAW and even TIG. My skills at stick/arc welding are not good but improving. It was so frustrating , I would have quit but I heard that next week (week six of eight) we focus on MIG! The first four weeks were spent learning terminology, symbols, techniques and fabrication. They had us build mini-Hibachi grilles….

View attachment 1812306

They had “plans” we had to follow to cut and shape the sheet metal. The designs of the bases were up to each student to come up with.

View attachment 1812307

That was fun. The welding booths there were often busy so I MIG’d them together at home.
This week, all the work was done in the shop at the college, that brings me to the point…..
As we age, as our eyes age, first we need more light to see….then we need glasses, then thicker/stronger glasses.
I’ve found that even still with strong glasses, I often need more light than I did before. The booths at the college have a fluorescent lamp behind the work that barely lights up the stuff you’re working on. I struggled with the work today….

View attachment 1812308

We all struggled with the stick welding but for me, welding blind sure made it a pisser. The younger guys didn’t have a problem with the lighting.
I stopped at the local welding supply to see about a welding hood mounted light. They had nothing. At home, I made this:

View attachment 1812309

It is fairly simple. Back when I was still working in construction, we often started work before sunrise and needed light to see and work. We al started wearing those LED lights attached to an elastic band with power supplied by rechargeable batteries. I just cut the bands off and screwed it to the hood…

View attachment 1812310

View attachment 1812311

Once welding starts, the lens darkens for protection but before and after, a dim area makes it hard to know where to get started.
Tomorrow I'll give it a try and report back....wish me luck!
@Kern Dog
It's cool seeing you persue the
professional side of this craft.
As a mechanical engineer, I applied
literally thousands of welding
processes to many, many, working
drawings. From city busses and
military vehicles, to deap sea
extendable risers. 40 years worth.
I've only taken classes in the mig
process.
Newer processes are being developed
but as with any task in the past,
being able to master and apply that
task is an art worth retention.

Check this out...
Still trying to find out what this
process is called, and where it
may be available. But it's pretty
impressive.

US Army's FMTV (BAE Systems)
x_fmtv_27609.jpg
Deep sea riser (NOV)
Image06272013102441.jpg
PS....Worked my way thru college as
a sheetrocker. Until a weekend
mishap changed that course.
Ended up in a rehab center but never
lost sight of the goal
 
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In 2014, I did the frame connectors in the red car with the car on jack stands! This was really difficult not only to do it but to do it well.

View attachment 1812573

The seam where the connectors meet the floor pan isn't welded, that is seam sealer, I only welded at the ends where the connectors meet the frame rails and crossmember.

View attachment 1812574

View attachment 1812575

Everything was smoothed over with a grinder using a flapper disc.

In 2020, I had a lift and did frame connectors in another car...

View attachment 1812576

View attachment 1812577

View attachment 1812578

View attachment 1812579

Being able to stand while welding sure did help but I still had a little trouble with the welds.
Nice work.
 
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