GMAW welding galvanized elbows

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I hate welding galvanized, I've had some experience with galvanized in a previous job and now with my second welding job. I'm butt joint welding big elbows in the vertical down position, and I'm having a hard time getting a nice weld in. While I know some guys say that it's almost impossible to get a good looking weld on anything galvanized, I find it hard to believe. I usually try to keep my gun angle at about 35 degrees. I'm running 16.5 volts and 190 wire speed, this is what the guy told me to run at even though I don't agree with him, he's the boss and he tells me to switch it back to his setting when I try to change it.   If I remember correctly I think it's 16 or 18 gauge. If anyone has any tips or tricks when it comes to welding on galvanized please share.
Reply:I always grind off the zinc off the surface before  I roll up my pieces. just an 1/8 to 3/16 off the surface but not too much into the metal because that makes it thinner. I found it to be helpful for me. I use a soft grinding pad like a 60 grit or so. see if he will let you grid one in the flat and set your welder to 17to 17.5 volts and around 150 on your wire speed and see if that helps. it should make it stop popping and look a little better. let me know what you think if you get to do that. And try 75 25 on your gas on thin stuff like that.
Reply:There is a place that builds irrigation pivots, and light poles near me... Welds all galvanized, and you can't grind it off. Guess they don't have enough of a clue to realize that GMAW just doesn't penetrate coatings that great... Hopefully your guy lets you get some of that nasty coating off.Miller Performance AD Helmet - Camo Edition Soon to have: Jackson HSL 100 - Forest Digi CamoMiller Thunderbolt AC/DC((Currently at welding school))
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Reply:Sounds like a previous job i had. Did the exact same thing.  They wouldnt take the time to grind off any of the galvanized though because everything was so rush-rush.
Reply:Soak it in vinegar to kill off the coating. The mexican muffler shop by me gets good looking welds on damn near anything they do. Those guys are great.Torchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:You need to be extra careful when welding anything galvanised, the problem is your gonna have issues with penatration unless you can grind back the zinc.Trying to weld on top of galvanised metal will just make a mess and blow up tons of spatter.Fume extraction or natural ventilation is a must, as is a mask which stop you breathing in the fumes. The fumes can cause irritation to the eye, nose and throat. The inhalation of excessive zinc fumes can place you or the operator over the PEL (permissible exposure limit) and cause metal fume fever. Ozone can also be emitted and prolonged exposure to ozone can cause lung damage
Reply:I would think that by the time you get enough heat to burn through the galvo, you're gonna blow right through that 16 or 18 ga. material. Any reason you can't grind it?I'm interested to hear about the vinegar trick that was posted though.IW Local 580 NY, NY