How to properly cut with electrodes?

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I need to cut 3, 1 inch holes in 1/2 inch plate. I don't have a plasma cutter or torches, so I'm limited to my stick welder.I want to know the best way of lancing through the plate cleanly, I believe I should use something like 1/8th 6010/6011 rod at around 200 amps. I'm not sure though since I have not a lot of experience doing this, I also only have one plate so I'd prefer not to **** up.I just realized this should probably be in the Machines, Tools, and Cutting methods subforum.Last edited by Vydunas; 05-09-2013 at 10:05 PM.Reason: I ****ed up
Reply:What about a drill motor and 1'' hole saw ??  Take it to local shop to have done ?
Reply:Originally Posted by BD1What about a drill motor and 1'' hole saw ??  Take it to local shop to have done ?
Reply:Originally Posted by VydunasI want to know the best way of lancing through the plate cleanly,
Reply:Originally Posted by DSWSort of a contradiction in terms. "Cleanly" wouldn't be my choice of words for using stick electrodes to cut. Jagged ugly mess is probably a better description of what you are going to end up with.Note this isn't really lancing, it's more just melting a hole. True lancing uses 100% O2 some what like a cutting torch.
Reply:Note they are called welding electrodes, not cutting electrodes.  I would suggest finding a friend with a cutting torch.  Otherwise...good luck.Matthew MortonTexas A&M '06Logsdon Seminary '13"Who Dares Wins""AFTF""WH2PH"SA 200 (Code: 5337)TB 302CP 302 w/22A Wire FeederMillerMatic 200Miller Syncrowave 200MillerMatic 252BurnTables 4x4 CNC MachineHypertherm 65
Reply:They won't be round.I would find someone local with the tools to get it done, and trade them a 12 pack for their time.
Reply:You are not going to be able to cut nice round holes with 6010 rod. You will be able to pierce and melt some holes but they wont be clean or perfectly round.JasonLincoln Idealarc 250 stick/tigThermal Dynamics Cutmaster 52Miller Bobcat 250Torchmate CNC tableThermal Arc Hefty 2Ironworkers Local 720
Reply:If the holes need to be fairly round and "clean", burn your holes a bit undersized, then use your grinder to smooth the edges.  If you can't use a grinder, try a grinding stone on your drill.I've burned holes with 1/8" 6010 or 6011, just don't move the rod around.  Burn through fast, high heat and stop.
Reply:Originally Posted by Vydunas I'm making a forge, so those holes are going to be for the air.
Reply:I have used 6010 to pierce plenty of holes in steel, but I have had better results with a stick rod made specifically for cutting by Certanium. Just don't expect bolt hole quality.JasonLincoln Idealarc 250 stick/tigThermal Dynamics Cutmaster 52Miller Bobcat 250Torchmate CNC tableThermal Arc Hefty 2Ironworkers Local 720
Reply:Originally Posted by DSWA worthy cause. If you were near me I'd help you drill the holes or let you use my torch.Of course if you had a forge, you could heat the plates red hot and drift some nice 1" round holes in the plates.
Reply:its doable, but your going to make a big mess that wont be weldable without a lot of die grinder time. Also 200amps is nowhere near enough. id say like 350-400 amps. 200 is still going to be trying to weld if you know what i mean.  i punched some holes in 3/8 plate an 275 amps barely did it220V AC/DC Stick MachineLincoln 125HDChop Saw, Grinders, Etc.Air CompressorTons of Hand ToolsFab Table, Half Bar Grate, Half Solid w/ Sears Vice
Reply:Where are you located anyway?
Reply:Originally Posted by mlasal1its doable, but your going to make a big mess that wont be weldable without a lot of die grinder time. Also 200amps is nowhere near enough. id say like 350-400 amps. 200 is still going to be trying to weld if you know what i mean.  i punched some holes in 3/8 plate an 275 amps barely did it
Reply:I used to use some gougeing rods at one of my jobs from a company called Nassau Electric, they were black rods specifically for gougeing purpose. At best they were pretty sloppy and not cheap.I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Well maybe drill a pilot hole with your dinky drill. That would help.
Reply:12 gauge shotgun and a slug. I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Originally Posted by weldermike12 gauge shotgun and a slug.
Reply:when in a pinch on site, i've used 7018 and 6013 welding rods, dipped in water and run at around 200 amps to gouge holes in steel, if your trying to do this cheap then i suggest trying it, by dipping the rods in water you'll end up with a porosity ridden, nice flowing mess instead of weld metal, so it's easier to clean up, use 2.5 or 3.2mm electrode (sorry, metric system here in aus, i don't know the imperial spec's)as said above, punch strait through and clean it up with a bur grinder and you'll end up with neater holes then if you try to cut the holes to size strait up with the rod's.of course be careful with with the wet electrodes, unplug the welder when putting them in the handpiece, and don't touch them with your gloves/hands once the welder is live.
Reply:Originally Posted by weldermikeI used to use some gougeing rods at one of my jobs from a company called Nassau Electric, they were black rods specifically for gougeing purpose. At best they were pretty sloppy and not cheap.
Reply:He is probably talking about gouging electrodes (not arc air carbon rods) although they are difficult to find and are expensive.eg Boehler makes FOX NUT http://www.bohlersoldabrasil.com.br/.../FOX%20NUT.pdf
Reply:any deceent welding supply store will have "slice rods"  they dont make real purty cuts, but they work.  I used to do a lot of work for a manufactured home outfit, the local code said all the foundation jacks had to be welded to a steel plate that was cast into the concrete foundation, then the jack threads had to be welded.  After all the welding, the tongues had to be cut off the frame and hauled away. There were probably 60 or so of these jacks under each home and the jobs paid a flat rate for each one so time to me was important to me.  Rather than dragging my oxy/acetylene outfit with me to cut the tongues, I just carried a handful of slice rod and cut the tongues that way, It took 3 rods for each tongue and only slightly slower than a torch.6 Miller Big Blue 600 Air Paks2 Miller 400D6 Lincoln LN-25's4 Miller Xtreme 12VS2 Miller Dimension 812 4 Climax BW-3000Z bore welders Hypertherm 65 and 85Bug-O Track BugPair of Welpers
Reply:I've done it with on 3/8 plate with a Lincoln 225.Don't remember what rod though?Its REALLY messy!
Reply:Originally Posted by VydunasI need to cut 3, 1 inch holes in 1/2 inch plate. I don't have a plasma cutter or torches, so I'm limited to my stick welder.I want to know the best way of lancing through the plate cleanly, I believe I should use something like 1/8th 6010/6011 rod at around 200 amps. I'm not sure though since I have not a lot of experience doing this, I also only have one plate so I'd prefer not to **** up.I just realized this should probably be in the Machines, Tools, and Cutting methods subforum.Originally Posted by weldermike12 gauge shotgun and a slug.
Reply:Wet 6010s actually work better than the Certanium cut rods in my experience. Seems to work best with the plate vertical, not flat. Start at the top of the hole and work down one side. then go back to the top and do the other side. The bottom will be ugly & slaggy!Still more of a field expedient method for emergencies; there are a lot of better ways to make holes in metal.JohnA few weldersA lot of hammersA whole lot of C-clamps
Reply:Well, I've acutally made some 1" diameter holes, using 6011 1/8" rod with my Lincoln AC/DC buzz box.  I made the holes into the thickest part of a railroad tie plate.  Those are about 3/4" thick at the thickest point (maybe 1" IIRC).  Anyway, it can be done.  I basically set the little Lincoln welder on "Shock & Awe" (AC-225) and kept the electrode perpendicular to the flat base metal.  I struck an arc and made a slow tight circle, about the diameter of a dime.At first, all the molton metal has no place to go, so it builds up.  Keep pushing the electrode into the molton blob without really going all "Chuck Norris" crazy on it.  Just keep the electrode steady and constantly moving and you'll burn through.  Once I burned through, I just made the hole wider by pulling the tip back toward the top edge of the metal and continued with my circle.   Once the circle was wide enough, I would push and gently force the electrode tip back down through the bottom.  It was messy, but definately doable.  I used a 7" grinder to smooth out the top and bottom side of the plate.   Again, it was very "3rd world country welding," but it did get the mission accomplished.  With more practice, I'm sure I could make the hole(s) better.  I only did the above "test" to see if it could be done.  Plus it was my day off from work, I was bored, slightly drunk and the old lady was not home    You know, the "perfect" welding day. When I'm serious about a project and I need a real hole for something, I've always pulled out the torch or plasma.   However, I understand that one must use what he/she has at the disposal and sometimes a hole from a stick welder is just... "GOOD 'NUFF."  Lincoln Power Mig 216Lincoln AC/DC-225/125Miller  625 X-Treme PlasmaMiller 211 Forney 95FI-A 301HF 91110Victor Journeyman O/PMilwaukee DaytonMakita  Baileigh NRA Life Member
Reply:BTW A 12 slug will not go through 3/8" plate so no way will it put a hole in 1/2".
Reply:you must be building a large forge..my firepot  has (6)  1/2"   holes i torch cut that are neither regular, nor perfectly round..one 3" pipe from the blower covers/feeds all 6 holes, are you running a seperate pipe toeach one inch hole? i would guess that some 6011 cranked up would do what you need if you have some plate to try it out on first..no reason those holes need to be pretty..Last edited by weldbead; 05-11-2013 at 09:37 AM.
Reply:Originally Posted by drujininBTW A 12 slug will not go through 3/8" plate so no way will it put a hole in 1/2".
Reply:So wet 6010/6011 focusing on as small a point as possible. I'll try this tomorrow.
Reply:It would take a while but I would draw out the circle and use a 3/16" bit and make holes all the way around your drawn circle, not pretty but way cleaner than a welding rod.The rod method is very messy and Lots and Lots of sparks everywhere you will also go through a few rods to say the least
Reply:I could send you a dozen holes. I save all the ones that I punch out on my Iron worker.  Mac
Reply:Works pretty good for what I need. You really need to jam the rod into the puddle.
Reply:I suggest this video:
Reply:Originally Posted by rschreckI suggest this video: