Welding thin metal sheets

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When tinkering automobiles people often use oxy-acetelene flames, which burns the Zn coating of the new piece of plate and the sorrounding area of the body.In order to avoid this, I think low voltage DC arc welding could be an answer. How do I convert my portable AC BLACK and DECKER arc welder to suit this job?
Reply:If by "arc" you mean an AC stick machine, while you can build a DC rectifier to convert AC to DC, stick is really the wrong process for welding modern body panels. Mig would be my 1st choice, OA probably #2 followed closely by tig. FC wire would be #4 and last would be stick.Stick is just too hot a process to weld thin steel. Most guys have difficulty with stick welding steel as thin as 16 ga using 1/16" stick rods on low amperage. I've seen a few very skilled welders who can do material a bit thinner, but the results are not pretty and you'd have a ton of work to do to finish of those welds. Even if you converted the AC to DC and tried to do DC tig on this, there are still plenty of challenges. Tig typically doesn't tolerate the paint and rust that is almost always left on body work no matter how clean you try and get it. Also it takes a lot of skill to do out of position tig without a pedal on thin sheet.Conversely I can probably get a new welder to learn enough of the basics to do a fair job using mig with .023 solid wire and C25 gas. Given the same practice time and skill level, the guy running mig would hav ethe best chance of being successful at thins..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:no idea how to convert your machine. if you want to do autobody I suggest getting a little 110v mig setup and a bottle of 75/25.bosses stuff:trailblazer 325maxstar 200my stuff:sa 200fronius transpocket 180100 amp Lincoln w/f97 f350 DITKevin
Reply:I used to have a very small ac stick welder and did a lot of sheet metal repairs with it. You need a very small rod and about 25 to 30 amps. if I remember the rod was about 9 inches long and prob 2 or 3 32nds of an inch. I loaned it to a bunch of friends and they did ok with it too. My quarters are still there ( on my 72 dodge charger) and look ok. So you dont have to have dc or a mig or a tig ( and lots of guys will tell you you they are absolutly manditory). But now that I have a mig it is easier  but if you have to get by with what you got then it is possible.Miller thunderbolt 250Decastar 135ERecovering tool-o-holic ESAB OAI have been interested or involved in Electrical, Fire Alarm, Auto, Marine, Welding, Electronics ETC to name a just a few. So YES you can own too many tools.
Reply:if you just plan on welding auto panels only just get a cheaper harbor frieght or northerntools mig that runs on 110v outlet and it capable of gas hookup  no flux core only machines. if you you plan on welding thicker material spend the  extra money for a name brand miller, hobart, lincoln 240v machine
Reply:As important as the machine you use is the type of joint should be your biggest concern. While a butt weld can be done an over lap seam with or without an offset or a flange joint will make your job easier.Miller xmt304,  Miller S22 p12, Miier Maxstar SD, Miller 252 w 30A, Miller super32p12, Lincoln Ranger 9, Thermal Arc 181I with spoolgun, Hypertherm 10000 ,Smith torches. Esab 161lts miniarc.