Filling in a gap with mig welder?

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I cut a panel out of a metal box so I could reinforce the space behind it.I tack welded the panel back in place but the kerf of the cutting wheel left a 1/8 space all around it.I was having trouble filling it in because it was 1/16" steel for starters so It burns right through even at lowest voltage. The second issue was the wire consistently ends up in the void and sputters everywhere. I resorted to filling in a small spot and just building upon it tapping on the trigger a million times. It's not very pretty and it was really exhausting. I'm sure once I grind it down flat it will look fine but was there a better way to do this?
Reply:Back it with a copper plate and weld away.(the weld wont stick to the copper)Bubble gumTooth pixDuct tapeBlack glueGBMF hammerScrew gun --bad battery (see above)
Reply:Is all of the paint, etc cleaned off?  Even at 1/16, doing this shouldn't be too difficult.  What setting was the machine on?-AaronJet 17.5" Drill Press1942 South Bend 16x84 Lathe1980s Miller 320A / BP --- 2013 Power Mig 2562012 Jet 7x12 Horizontal BandsawVictor O/A Setup
Reply:Lowest voltage, low wire speed I had to move slowly.I didn't make the straightest cut so some spots I got away with an inch at a time but rarely.Can't back it with copper it's sealed on the backside but that's a neat idea il have to remember that.The actual gas was 1/8" all around. I tried keeping it in the puddle to keep the arc but the puddle quickly dripped down and blew through the metal if I tried to keep it going for more than a couple seconds.
Reply:Take a 1/16" rod( or a stick of R45), knock the flux off, and dab it in the puddle as you weld. More like tac  tac  tacBubble gumTooth pixDuct tapeBlack glueGBMF hammerScrew gun --bad battery (see above)
Reply:You could also just lay a 3/32" rod in the gap and weld over that.A few weldersA lot of hammersA whole lot of C-clamps
Reply:Lowest voltage and wire speed does not mean Proper voltage and wire speed.. Could be part of the problem with controlling the puddle. Short welds and skipping around will probably have the best results for you but try to dial in the settings first. Welding downhill is an easy way to fill gaps and adding some filler like the others said can help.Airco Ac/Dc 300 HeliwelderMillerMatic 200 (stolen)Miller Maxstar 150STLMiller AEAD200LE (welding and generating power) Hobart MIG
Reply:What wire size ? what gas ? or are you trying to do it with flux core wireIf it's thin be careful not to warp it by overheating itIf it's like sheet metal on a car you will have to do a series of tacks not just burn it in one place going around it weld a little here then jump to a spot somewhere cool a weld a little otherwise it will warpBacked my CATMA over your CARMA oops clusmy me  What would SATAN do ?? Miller Trailblazer 302 AirPakMiller Digital Elite  Optrel Welding HatArcair K4000Suitcase 12RC / 12 VSHypertherm PM-45Rage 3 sawRusty old Truck
Reply:[QUOTE=BrooklynBravest;3254841]I cut a panel out of a metal box so I could reinforce the space behind it.I resorted to filling in a small spot and just building upon it tapping on the trigger a million times. It's not very pretty and it was really exhausting. QUOTE]The Tap, tap method is not a bad solution, if you get good at making your series of tacks right at the point at which the puddle touched the piece on the right, then nearly immediately, the same spot on the piece on the left, back and forth.When you get your timing right, the previous tack will not quite have cooled, so it can sort of flow together, and make a presentable weld.I have also had to run a bit super fast down one side of the gap, then very fast down the other, just to get some "meat" on the edges to aid in bridging the gap.Have fun!
Reply:Originally Posted by Silicon-basedYou could also just lay a 3/32" rod in the gap and weld over that.
Reply:Originally Posted by SuperArcThat's what I did yesterday while welding two 20lb propane tanks together.  My gaps were big is some parts that I just tacked  a curved piece of 7018 (chipped and wire wheeled the flux off first) in the gap from the inside of the tanks and welded away on the outside. Looks good.
Reply:Would spooling out a couple strands of the actual wire and tacking it in place the long way inside the gap help me out at all or will it just disintegrate the second the arc hits it?
Reply:1/16th shouldn't be any real issue even on gauge material. What machine, wire size, and type (solid or flux core) are you running?
Reply:It's a 1/8" gap not 1/16"Hobart autoarc 130Solid .030 wireC25
Reply:My mistake on the gap. I prefer 0.023 wire on thin gauge material. Can you build up the plate before installing it?
Reply:Are you laying the piece flat on the table or is it standing vertically? Try vertically and point the nozzle up so the puddle is traveling Down the gap. Try not to do more than a half inch at a time to avoid warping. Hope that helps...