Welding EMT

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Hello. I am looking for some how-to advice concerning welding galvanized thin wall electrical conduit. I am making mostly butt joint and coped welds. I will be using a 110v. Lincoln welder. Does anyone have any expierence or know how regarding this? Thanks!
Reply:Fluxcore or do you have the gas kit for it?Fluxcore should weld right over the GalvySolid wire and gas, you'll have to remove the galvy with a Flap Disc on a grinder- easy.Just wear a Mask as the Dust can make you sick and keep yer head outta the fumes when welding as the Fumes can make you sick also. You should keep yer head outta the fumes when welding anyway-says so right da instructions It is very thin so you'll have to have some patience.Ed Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:You don't mention which size of EMT, as wall thickness will vary, but I usually use the GMAW process after flap-disking off the thin electrogalv layer.  FCAW works well, but you just have to be a little better at controlling overpenetration.  I build stuff with it all the time, as I always have it laying around.  NOT a very good structural component unless you get into the 1-1/4 and larger stuff, depending on what you are making with it, though.
Reply:I'll be welding with flux-core...any advice on wire thickness?...also will be using '1 material...thanks for your info guys...much appreciated!
Reply:.030" would be my first choice, but .035" will work with a little more skill.