Welds - looking for advice

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OK, here are some flux core welds from a couple nights ago.  I've only been welding a VERY short time.Please help me out with any info possible.  Seems like I am getting lots of craters(welds arent so flat)  Is that due to travel speed... or not being smooth??  Or do these look OK?Material:1.5 x 1.5 x 3/16" angle iron.Welder:Hobart 180Settings:Polarity = DCENVoltage = 3Wire Speed = 60Wire = .030 Flux core  (harbor freight!   )
Reply:Oh, I will be switching to gas soon.  dont have the $$ yet... friggin bender broke my bank!  lol
Reply:Really looks pretty good.  The ripple/ridges look a bit coarse, must be due to the torch manipulation you are using, not a big deal but something to work on.The BIG deal is the crater left at the end of the weld .  When the arc is stopped suddenly, the crater that is left cools/solidifies rapidly, producing stresses in the shallow weld that will tend to produce a crater crack.  Even if the crater is not cracked, it is very susceptable to initiating a crack in the future that could run right trough the entire weld.You need to pause a bit at the end, maybe circle the torch around, and fill the crater.
Reply:Yea, I noticed that.It seemed like when I got to the end... it started blowing past or thru.... didnt feel the same.  I would just stop.So should I kinda reverse the travel a bit and hold it a second longer???  Or???
Reply:Yep, what you said.
Reply:If you are just learning to weld and using flux core, I say you doing great. Welds look good other than whats all ready been pointed out. Follow Pulser's advice and that should be it. Good work.Miller DVI2Lincoln Precision Tig 225Thermodynamics Cutmaster 38Everything else needed.
Reply:Looks decent, start from the end and work toward your center. Stop buying HF wire! John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:Ok ,thanks guys.  Once I switch to gas and start welding my tubing, I will post up the results.  I just want to have it nailed before I start my cab cage on my Ford Ranger. Gonna start with a bumper.  I do want the cage to be safe.  ;-)
Reply:deleted: posted in wrong page--------------------GMC WLDR 140A Stick Arc cheapskatenow with 90% more burnthrough
Reply:OK..Let me get this straight...Your gonna build a cage for whatever..Is this going to be inspected?What are we using for tubing?I just dont want you to waste your time or $$$$ by doing something that will not pass tech...Or that will not put up with a roll over.. ...zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Hey FasterNU...glad you found the forum!Your welds are looking good for a beginner...Pulser has some great advice, watch the tie-off...and so does Microzone, stop buying HF wire!!  ..and zap, he's building a cage for a Prerunner and I don't think he has any plans to race it.- Paulhttp://all-a-cart.comWelding Cart Kits and accessories
Reply:ZT fab is correct!No plans to race right now .... But I do want this truck to be as safe as possible.  I've been riding motorcycles my whole life and want to move into trucks as I get older(30 now)... mainly because.. it's "safer".  I guess "safe" is all relative though, right!?  I'm still recovering from a broken ankle, and as you can see in the first pic ... my brother has a broken neck right now too ... oh and a machete.    lolMaterial will be the following:bumpers and bedcage = 1-3/4 .120 MildCab Cage = 1-3/4 .120 DOMI just got my bender delivered yesterday, so all I need to do is switch to gas and buy some material.  damn this new hobby is expensive already!!Vehicle = 93 Ford Ranger, STD cab short bed, 2.3L 5 speed.Here's a few pics.  Also included a dirtbike photo from last weekend at Superstition...-Aaron
Reply:Oh, I have been F'n around with schedule 40 pipe in the meantime(I think 1-1/2 ID??)I did my first notches and junctions the other night(using a band saw and a grinder because I dont have hole saws yet)  I made a 90 and then put a 45 into the same joint.  My notches came out nice.. took a long time though.BUT, my welds came out like complete crap.  Welder seemed to be acting up a bit.  Not sure exactly why... I did run out of wire right at the end though.  Not sure if the tip was clogged or what.. but it would just stop feeding/arcing in the middle of a weld.  I'll post some pics later.  Probably good for a laugh or two.I have LOTS of dumb questions for you guys too!!!  So be prepared
Reply:We're ready. Any type of question is okay...even if it seems dumb, all of us have probably run across the same issue at one time or another.John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:Read my signature......ask away.  - Paulhttp://all-a-cart.comWelding Cart Kits and accessories
Reply:I'd say your on the right track... when you switch to gas you will probably do fine.   As far as a cage project???  Yeah like I said you'll do fine.  Keeep at it!!! You have the technique down pat.  Don't let others confuse you on your ability..    Yeah flux core is looked down upon ...w/ I could say with good reason; however, do the cage project w/ gas and follow the specs and youl'll be proud weld it like you own it
Reply:Sounds like s cool project, what are you doing for front and rear suspension?
Reply:looking good  FasterNU nice looking welds flux core is not real big in aus for home user'sbut your on the right track and a great looking project it might just be me but if I can't use mig with gas I grab a real welder a stick  now that will stir the possum   aussie saying for a sh8t stir but your going well FasterNU keep at it and keep the pics coming we love pics  Creative metal Creative metal Facebook
Reply:OK, you want pictures.. you get pictures!!!  I'll save the stupid questions for later.  Biggest question is how the hell you weld in the tight joint junctions.. like the 45 i did.  Seemed super hard to fit the gun in there...(had to hold from far away)First notch ever.. First couple junctions:After trying to beat the junction off... i think every neighbor came out to see what the racket was all about.   I wasnt succesfull in breaking it off.
Reply:Here's the lousy welds I was getting with the on/off pauses I spoke about.  After reading other threads it makes me wonder if i had a poor ground connection:First 45 junction ever.  Could NOT get the welder to work right. Notch was super good though(forgot to take photo)OH, this is all schedule 40 pipe I believeHere is the weld from where the problem of the welder just cutting out was the worst...
Reply:Originally Posted by maxyedorSounds like s cool project, what are you doing for front and rear suspension?
Reply:The 4'th pic up^^^^The welds do not meet in the middle... But lots of the others look very good....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:OK, stupid questions time.1.  How many times do you stop/start when you experienced welders weld a tube junction.  Does it matter??2.  How do you make an X within a square using all tubing.  Such as [x]IE: Say you had 4x pieces of tube all butt welded in a square.  [ ]How do you notch and fit in the first diagonal? [/]  Or the second and third pieces needed for that matter?  Won't they be too long to fit in the square if the joint/notch is tight??I can see if maybe you put it all together at once, and then weld... but is that the only way?  Or can you add in the diagonals later?
Reply:Are you talking about doing an exhaust crossover?John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:no... structural tubing for a roll cage. 1-3/4" .120 wall to be exactOk, I'm new to the site, but not new to welding cages, so I figured here is a good place to say hello and maybe help out a little.1. How many times do you stop/start when you experienced welders weld a tube junction. Does it matter??Doesn't really matter and unless you've got the climbing skills of a monkey, tail and all, you won't be able to weld around a tube on a cage without stopping. Just don't get into the "stitch welding" fad that seems to be taking hold with a lot of new guys.2. How do you make an X within a square using all tubing. Such as [x]IE: Say you had 4x pieces of tube all butt welded in a square. [ ]How do you notch and fit in the first diagonal? [/] If you don't have a tubing notcher, you'll need to get one.  Basically I measure the length I'll need for the first diagonal and cut my tube a 6-8 inches longer.  Then I'll lay out where the "X" will go and tie a string in place of the tube and take the angle.  Set that angle on the notcher and you're good to go.Or the second and third pieces needed for that matter? Won't they be too long to fit in the square if the joint/notch is tight??I can see if maybe you put it all together at once, and then weld... but is that the only way? Or can you add in the diagonals later?The second and third pieces of the "X" have to be notched out for the first piece to pass through.   After you lay out the "X" you'll want to fit all the pieces and tack them together before completely welding.Here's a few pics to help explain:This chassis is all 1.75" x .120 and .095 wall DOM-Jason Attached Images
Reply:Excellent tutorial there TSOR.  Good work.
Reply:FasterNU,The joints need to be tight for a stronger weld.  Sometimes you can fit pretty tight and pound it in with a BFH (Big F*****' Hammer).  Since you're talking roll cages, I'll assume your talking about X'ing the main hoop of the cage.  What I usually do is put in a crossbar from the drivers side upright to the right side upright.  Then put in the diagonals, meeting the "toes" of the diagonals on the top or bottom of the cross bar, possibly just a little apart (makes fitting MUCH easier).  The left side of my pic will help explain it.  Getting the first cross bar in I usually just get it in as close as I can on an angle (like on the right side of the pic), then knock it straight with the BFH.  Put the crossbar at the right hight for your should harness mounts, then work from there.Edited to add:  TSOR does such good work, I'm just having him come over and do my next one!! Ed Attached ImagesLast edited by BigEd36; 03-25-2007 at 02:22 PM.When the  drops the  stops!Check out my website at:  Tombstone 180 ACHandler 120Millermatic 210Powermax 380Harris & Victor torchesSawzallChop Saw
Reply:Yeah..Thats how its done..Very nice demo..I would never recomend "stitch welding" a cage  Its for really big stuff..1 filler pass on a cage is sufficant.....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:So correct way is to start and stop on the middle of the tube? like tutorial shows?My Babies: HF Drill pressHF Pipe Bender3   4.5" Black and Decker angle grindersLincoln Electric PROMIG 175that´s it!
Reply:Originally Posted by elvergonSo correct way is to start and stop on the middle of the tube? like tutorial shows?
Reply:TSOR, good advice of the "stich" style of welding, I think of it as "multi-tack" because that's all it is a serries of tacks that have poor penatration and are prone to breaking. A lot of people seem to be doing it, probably becuas it makes it so easy to lay a pretty weld, but god help you if you weld a cage like that and roll the car/truck. Nothing scares me more than poorly welded cages, I run chase at offroad races and help ut anybody broken or crashed that I see, I just hope I never have to see a crushed person because the guy that welded his cage wet for looks over function, not sure I could handle that.
Reply:Hey max......who do you chase for and what races do you go to?I chase for Vildosola, Trophy Truck #4 and Pro Truck # 204.- Paulhttp://all-a-cart.comWelding Cart Kits and accessories
Reply:OK, just in case you care, here are some updates.OK, finally got my bender going. My first bend ever after bending 1x tube 90 and then 180 for BendTech EZ calibration.  I made a custom part using the SW ... pretty much guessed with the angles ... but it turned out nice!Mounted on truck:First welds with gas.  Frame caps were done with the last bit of flux core I had.and a cool welding pic:
Reply:I'm not sure if you have heard of www.pirate4x4.com but they have some great cage advice, as far as notching, bending, measuring, and welding.  I'm a bit behind you as far as welding (I've only laid about 2 ft of bead now) but I'm going the flux route on practice stuff until I get better.  I'm a little more nervous than you though as I havent even thought of bringing that thing near my truck yet, but that's because I plan on welding leaf mounts etc, and I'm more worried about those breaking off because at that point I won't have a cage welded and would most certainly roll in a bad situation.  Your welds do look nice though, mine are really spattery and seem to only penetrate half the time, I need to get a more consistent welder.
Reply:Hey FasterNU, how bout post some more info about that bender in the tools forum.  Looks like it makes pretty slick bends.  Beads are coming along pretty nice.  One thing you may want to consider for the cage is drilling a small hole in the pipe where the fish mouth (notch) will but up to it.  Reason; as you weld, if the other end is sealed, pressure builds up in the pipe due to heat, gas vapors, what have you, as you get closer to sealing the weld, the gas has one place to escape, and that's out through your weld puddle, not a good place to have porosity.  The hole allows the gas to escape.
Reply:Ah ha, I found a tool that might help with laying out those notches.  It's on www.eastwoodco.com, the PipeMaster Tubing Adjustable Pipe Template.  Works like a contour guage for body work, it's just round, then you slide it over your pipe and draw the line for your notch.  Thought it might help out.
Reply:looks like you are pushing your weld instead of draging helps to drag when runing fluxcore.
Reply:I almost always drag.  As for the question about the bender... it does indeed make sine nice bends!  I will post some new pics soon.It's the JD2 Model 3 bender.  A good deal compared to most and as you can see it works like a champ.  I seem to be having some minor trouble with mine(parts end up being a tad wider than designed.)  I believe this is because of my calibration bend.  It calculates how much it stretches the material etc.  My advice ... make sure you calibrate well!!
Reply:here's the progress:
Reply:JD2 also makes a sweet notcher for $250.00Pirate4x4 is definately the place to learn about bending.Here is the tool section with links to great stuff - http://www.pirate4x4.com/forum/forumdisplay.php?f=61Trevor" Three-fourths of the Earth's surface is water, and one-fourth is land.  It is quite clear that the good Lord intended us to spend triple the amount of time fishing as taking care of the lawn." --Chuck Clark