New to welding. O/A Lap joint question

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Hello. I am new to welding. I bought a Victor Performer, several tips (00...3) and bought(not rented) a couple of tanks. Everything works well. I bought and read, cover to cover, the 'How To Weld' by Todd Bridigum. Excellent introduction. Watched every video on safety and practice on youtube that I could find. I went O/A first as I need to heat and cut occasionally as well. I went through the beginner exercises, pushing a puddle across a plate, then filler rod, then some simple joints. However, when I go to actually make a tool, I ran into some technical problems. I needed to make a motorcycle flywheel holding tool. Used an old 1/8" clutch plate and some similar thickness flat steel about 1/8" thick and 1" wide for the handle.  I wanted to simply clamp the 1/8" 'handle' to the face of the clutch plate. My first attempt, the #2 Victor tip was just not enough heat. The base clutch disk would glow red hot, the handle would melt, but could never get the clutch plate to melting point. So, bought a #3 tip. That was enough to melt the clutch plate, but... It was too much heat for the joint because the handle just got too hot and started to melt away where the bead was going in. It 'worked' but looks pretty ugly. So, is there a trick to this? I thought:  first heat the clutch disk base to cherry red, preheating it, then focus the flame at a more obtuse angle, basically, 90 deg to the clutch disk vs 45 deg into the joint. I guess the question is: when attaching a thinner tab or strip of steel to a base which will absorb much more heat, thereby staying cool, how can a proper lap joint be achieved? Remember, this is my FIRST non practice project. Go easy on me. Yes, the steel 'was' clean when I welded it up, but has since rusted. Many thanksMichael
Reply:I know it doesn't seem like it, but for what you are trying to do, for a very first attempt, the result is not that bad.If it were a practice piece, you might even be proud of it!Easiest answer is to braze it rather than weld it. You will be ecstatic with the difference, the ease, and the result. (especially with fillet brazing)Next answer might be to use something a little wider or thicker for the handle, for the obvious reasons.Less appealing answer, keep practicing.Hobart Beta-Mig 2511972 Miller AEAD-200LEMiller 250 TwinNorthern Ind. Hybrid 200Longevity Stick 140Longevity Migweld 200SThermal Arc Pak 3XR
Reply:Geezer Bill,Thanks. I bought some brazing rod to try that chapter as well. Seems like it can be very strong and useful. I will try it today. Thanks for the advice. Even in the book, his lap joint is ugly when compared to the beautiful tig welds later on. I will get a tig setup going here when I feel confident that my O/A skill warrants the step up. Welding super thin sheet metal is also a real challenge. Burns away in an instant, creating yet another mini-project. I am also experimenting with dialing in smaller/larger flames within a single tip's capacity. Had my first torch pops too. Startling to say the least  Many thanks Bill,Michael
Reply:TIG welding laps is no walk in the park either, although it is easier than gas welding. I think laps may be the most difficult joint to learn. I had better success on tee and butt joints with the TIG. I gave up on gas welding after a few weeks. I just didn't have the patience for it. Your OA results look better than mine. Brazing is a good answer on a lap joint. I recall reading somewhere that brazed joints have up to 85K tensile strength. They are not weak when done correctly.Miller Multimatic 255
Reply:I am more interested in establishing and moving a puddle.  I would get a puddle started on the disk, then move the puddle to the handle. Start on the edge on the disk. The size tip will determine how close to the handle you can begin your puddle. How much pressure you using? What type metal is the clutch disk?  Popping is a result of too much heat at the tip.  I would imagine that 90 degree angle causes large heat buildup, could be incorrect pressure too. Good luck.Last edited by tapwelder; 11-29-2015 at 12:23 PM.
Reply:Originally Posted by tapwelderI am more interested in establishing and moving a puddle.  I would get a puddle started on the disk, then move the puddle to the handle. Start on the edge on the disk. The size tip will determine how close to the handle you can begin your puddle. How much pressure you using? What type metal is the clutch disk?  Popping is a result of too much heat at the tip.  I would imagine that 90 degree angle causes large heat buildup, could be incorrect pressure too. Good luck.
Reply:You are doing well. Post your location and up close pics of your project. Lotsa folks like to help around here. And welcome.Arcon Workhorse 300MSPowcon 400SMTPowcon SM400 x 2Powcon SM3001968 SA200 Redface1978 SA250 DieselMiller Super 32P FeederPre 1927 American 14" High Duty LatheK&T Milwaukee 2H Horizontal MillBryan
Reply:I am in Orlando, FL. Near Winter Park. I will get some closer shots of this franken-weld. Thanks..  Glad to finally be among you, even as the most green apprentice. Welding has always a been an esoteric art form for me. I waited and waited to learn. Tried to get started in a local junior college, but the closest one appears to be 30 mins out. Life circumstances just don't allow for that level of weekly commitment. So, reading and practicing and asking is all I have.Thanks again! Michael
Reply:Originally Posted by blackbird939I am in Orlando, FL. Near Winter Park. I will get some closer shots of this franken-weld. Thanks..  Glad to finally be among you, even as the most green apprentice. Welding has always a been an esoteric art form for me. I waited and waited to learn. Tried to get started in a local junior college, but the closest one appears to be 30 mins out. Life circumstances just don't allow for that level of weekly commitment. So, reading and practicing and asking is all I have.Thanks again! Michael
Reply:Here's a clutch holding tool for a small Yamaha twostroke. Made it this summer, an old clutch disc and lawnmower pieces brazed together using O/A. I stayed away from welding because welding the relatively thin clutch disc would jeopardise the snug fit over the clutch center. I'm sure welding could have worked too, just a bigger risk of having to grind weld off to get the tool to fit.For welding something like that, I'd also go for melting the plate first, possibly aiming the flame slightly away from the handle to prevent it from melting too early, and then moving up on the edge to melt that too.
Reply:Originally Posted by blackbird939Tried to get started in a local junior college, but the closest one appears to be 30 mins out. Life circumstances just don't allow for that level of weekly commitment. So, reading and practicing and asking is all I have.