quick hole fixing question?

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I have about 10 harrow disc blades that I'm going to make into Discos for Christmas presents for my family and a couple friends.  Part of the process is welding the hole shut.  The holes are 1.5 inch square holes.  I've cut small 2 inch square "patches from thinner steel.  Tacked it on the back and filled in the whole from the other side.  I've also suspended the disco and welded the whole shut.  And ground it down flat on both sides.  I only have a SMAW welder at the moment.  Id like to buy a mig but that's down the road.  A couple of my buddies told me I need to find a "carbon block". They say it is used to fill in holes. According to them you use it like a backing similar to my 2 inch patches.  But it does not stick it comes right off.  I can't find this any ware on the internet.  If its real it would make it easier to fill in these holes.  Also they suggested using 2 electrodes one in stinger and one in hand like Tig welding.  Are they out of their minds?  Or does this so called block exist and can you use two rods at once?  Thanks.
Reply:Yes they do exist, but are a bit pricey if I recall correctly. As for two rods at once, I think that's what some refer to as 'Kentucky TIG'.Lincoln Idealarc 250 (circa 1962)Lincoln Weldpak 155 w/Mig KitLincoln Squarewave TIG 175
Reply:What do they call these blocks?  I'd like to find out what they cost. Thank you.
Reply:I've used copper plates to back up holes when filling them with mig. For stick, I'd want something thicker than the copper flashing I usually use. Most holes I've filled with a copper backing were 5/8" and smaller though. Personally I'd simply fab a square piece of steel the size of the hole and weld it in myself. I'd buy a foot or so of 1 1/2" wide 1/4" or 3/16"  flat bar stock ( or whatever matches the disk thickness) and then just cut off 1 1/2" pieces. It would be faster than trying to fill such a large hole.Last edited by DSW; 10-15-2012 at 05:49 PM..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:I was told buy an old welder that to fill a gap up use a piece of flat copper behind the hole or wide crack and the weld  won't stick to the copper ,it worked for me. i used a piece 1" copper pipe and flattened it out with a hammer and put it behind a wide crack and it worked . give it a try what do you have to lose .good luck chris.
Reply:brass works also - something thicker than 1/8" would be best and cheaper than copperThermal Arc Fabricator 2101970 Lincoln RedfaceMiller 150 STLStill need a Syncrowave and a plasma and a milling machine and a lathe and a bigger shop and a....
Reply:So copper or brass won't stick?  I wander why that is?  I would think the heat would melt it.  I gotta give this a try!  I may still just do the plug thing but I want to see if this works.  I've been told that doing this also helps when welding thin peaces of steel together.
Reply:Originally Posted by Zapzoo  I've been told that doing this also helps when welding thin peaces of steel together.
Reply:If you decide you still want the carbon plates, you can get them here:https://weldingsupply.securesites.ne...71:UNDEF::::PPpersonally, I just use the copper.
Reply:David Sheffield, Repair Tech, 1434 E. Benge Rd. Ft. Gibson OK 74434, Ph. 888-478-4558 or 918-458-4558 No web site.This guy had a write up in Farm Show magazine a wile back.  They sell carbon flats and rods of different sizes and have kits as well.Dan
Reply:Seeing as you can braze with copper, it's certainly possible to get it to stick. Copper melts at a somewhat lower temperature than steel, but it also sinks away heat very quickly.Lincoln 175HD
Reply:I have used two rods before never on anything that thinMillermatic 252millermatic 175miller 300 Thunderboltlincoln ranger 250smith torcheslots of bfh'sIf it dont fit get a bigger hammer
Reply:I have a chunk of graphite a friend gave me when I need to do some filling. Nifty stuff. Doesn't stick at all. It doesn't seem to wick away the heat like copper. I was skeptical until I tried it. You can also machine/carve it into any shape required.You can also get it from Mcmaster-Carr:http://www.mcmaster.com/#graphite/=jqm0c9
Reply:There used to be a Nickle mine about 50 miles from me.  When they closed it down a few years ago I happened to acquire a  piece of one of their anodes about 9 inches in diameter and a foot long. They are solid graphite with a copper coat on the outside. Work just like a carbon arc only without the air. they actually run in an argon atmosphere. I just cut a slab off when I want a backup. Like someone said it machines really easy and you can cast aluminum in it also.  Mac
Reply:Originally Posted by forhireI have a chunk of graphite a friend gave me when I need to do some filling. Nifty stuff. Doesn't stick at all. It doesn't seem to wick away the heat like copper. I was skeptical until I tried it. You can also machine/carve it into any shape required.You can also get it from Mcmaster-Carr:http://www.mcmaster.com/#graphite/=jqm0c9
Reply:I found some 1 inch copper pipe coupling about 1 1/2 inch long it is about 1/8 inch thickness.  Pounded it flat worked great!  I also found foot long peace of brass that works but it warped under the heat.  Not a big deal they both worked no need for expensive carbon blocks.  Thanks.
Reply:When doing the same thing (filling in the square holes on plow disc) , I used a piece of 1/4 x 2 aluminum flat bar as a backer
Reply:Be careful about getting brass too hot, you can end up boiling the zinc out of it which is nasty.Lincoln 175HD
Reply:i must of missed the question but i always put a piece of steel in the hole and then weld it inLincoln Power Arc 4000 Thermal Arc Fabricator 252 iThermal arc 186Thermal Arc 26 tigTweeko 200 amp spool gunHobart AirForce 400WP-17V-12R
Reply:Please excuse my ignorance, but what is a "Disco"?? I have several old and used disc blades on the farm and might be able to figure out a use for them. A couple of them have been used for a base for a stand for a vice and another for a reloading machine with a pipe as a vertical shaft. Is that what a "Disco" is?Google shows a Mexican Disco as a fry pan much like a Chinese Wok.  Thanks.
Reply:Hi GWD,There are differents options of a "Disco", the following is one that I like:http://weldingweb.com/vbb/showthread.php?t=112481Best regardsMauricio
Reply:Originally Posted by mauricio_daniel_62Hi GWD,There are differents options of a "Disco", the following is one that I like:http://weldingweb.com/vbb/showthread.php?t=112481Best regards
Reply:[QUOTE=GWD;1713421... Google shows a Mexican Disco as a fry pan much like a Chinese Wok.  Thanks.[/QUOTE]Sometimes called a "Texas Wok".   I've been meaning to stop by the local Agri Supply store and get a harrow disc.  The new ones aren't too expensive in the smaller sizes.Do keep in mind that they are somewhat high carbon steel, so pre- post-heat or at least let cool slowly if you don't want cracks.  Low-hy all the way."USMCPOP" First-born son: KIA  Iraq 1/26/05Syncrowave 250 w/ Coolmate 3Dialarc 250, Idealarc 250SP-175 +Firepower TIG 160S (gave the TA 161 STL to the son)Lincwelder AC180C (1952)Victor & Smith O/A torchesMiller spot welder
Reply:I've all ways have a chunk of copper in my bolt bag for welding up bolt holes in beams and channels. 3"x2x1/4" . Harbour Frieght has a paddle with a copper plate and handle that works great. Cheap! I think it was under $5. The copper was worth more than that.
Reply:Basicly a harrow disc blade used for cooking.  Works real well.  Around here people use them to make everything from breakfast burritos to fajitas.  Mostly mexicanish food however I've cooked all kinds of stuff with them.  I've used them to make stir fry make hamburgers and all kinds of other stuff.  I was looking for options on how to close the 1.5 inch hole in the center.  A lot of people weld a "patch" on the bottom just slightly larger than the hole then fill it in.  I don't like this method, it works I just don't like the look. Others try to plug the hole and some just weld it shut.  I've tried all three.  I took one suggestion from above about the flat stock.  It made the patch job a lot quicker.  Which is probably what I'm gonna do.  My only concern is fully penetrating the steel.  If there is a gap or air pocket I would think the constant stress of heating and cooling may cause it to fail and crack or something.  Maybe not but I've thought about it.  I've also got some other projects where I may be filling in holes so I was looking for options.  The copper peaces are now a requirement in my tool box.  It made filling in the hole so much easier!  Thanks.We tried this and used lo hi and also ss etc etc pre heated slow cooled....we didnt want any cavities due to it being used for food prep....in any event after burning up all kinds of $$$ consumables and constantly having hairline cracks, we went to the store and bought one for $18.00