Welding galvanized pipe

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I am trying to weld galvanized pipe .095 wall  2-3/8 for a gate support.  I can get it to stick together but its not pretty.  I have a Miller Bobcat 225 and a Miller 130 mig machine.  Which would be best to use? any special rod / wire to use? Any advice would be great.  ThanksI tried to post this before but I think I did something wrong.  If it is here twice sorry my bad.
Reply:grind off galvi an weld DON T breath fumesidealarc 250/250 ac-dc tigidealarc 250/250 ac-dc tig #2 used for sticklincoln sp100hh125dual arbor grinder polisher30 yrs of hand tools52 pitch blocks 6p-26prake gauge -pitch gaugeG&D prop repair 918-207-6938Hulbert,okla 74441
Reply:I've welded some galvanized stuff that was on a dog kennel. As prop-doctor says, grind off the galvanized coating and try not to breathe the fumes.You will be better off my using the MIG and small wire. To keep heat build up to a minimum, I find that laying a series of pulse welds works better. I don't have pulse on my MIG so it's manually pulling the trigger for a brief moment and then letting it cool for a few moments before moving on.I'm not a pro welder, but that's the method I use to get better results without burn through.PapaLincoln Idealarc 250 (circa 1962)Lincoln Weldpak 155 w/Mig KitLincoln Squarewave TIG 175
Reply:I am thinking chain link fence, terminal post as the line posts probably would be 1 7/8 ith a top pipe of 1 3/8 or 1 5/8.  If that is the case there isn't much galvinization on the pipe.  There are four different grades of that stuff, you posted the thickness but sometimes buying that stuff at home depot and pricing against a fence company isn't a fair comparison.  There is a special paint to use after the fact and minimum spatter probably would be what I would look for.  I made an 8 foot gate a few years ago and can't remember what I used,  Might just have burned it with a torch and wire brushed.
Reply:.095 purrdy darn close to 1/8 " if your running FC mig light grind an you could just weld it an be done, then paint with a cold galvi paintunless its hot dipped galv ---then grind to real steel  an weldidealarc 250/250 ac-dc tigidealarc 250/250 ac-dc tig #2 used for sticklincoln sp100hh125dual arbor grinder polisher30 yrs of hand tools52 pitch blocks 6p-26prake gauge -pitch gaugeG&D prop repair 918-207-6938Hulbert,okla 74441
Reply:Wear a respirator, & don't bother grinding it.  crank the heat up, & burn through it.Leathers are a good idea too, it's gonna spatter like a mofo..I used to weld galvy (1.5 spools of .035/day) every day, 6 days a week making prefab wall panels.What a crappy job that was...We didn't grind anything, it would have just taken too long.Buy American, or don't whine when you end up on the bread line.
Reply:in the world of pipe that stuffs not even pipe...as pointed out  .095 wall is less than 1/8"..are you sure it has enough assss to support a gate? of  course there's  gates and then there's Gates..
Reply:Grind it off.  Weld it.Don't breathe the white smoke.If you breathe enough of the white smoke it gives you the sh*ts and the shakes.   If you grind the outside, the  galv is still on the inside and will burn when you weld.  Don't breathe the white smoke....Use what ever machine you are best with.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Being a beginer what, why, how come, not to breath the fumes. Im sure its best to avoid all the general fumes that come from us welding, but why do I hear so much about the galvinzed stuff. I have some 20 ft sticks of galv angle here that I was going to use in building a small tire rack for my spare tires. Maybe Ill rethink this. Then again, I cant find the spare time to build the spare tire rack Learning one rod at a time
Reply:A pro welder told me to not grind and just use 6011 rod.  I made a firewood rack from old galv fence posts, 1 1/2" diameter .125 thickness.  Used my TA 95 s at 80 amps with 3/32 6011 as the base weld, then covered it with a nice 7018 weave bead.  Worked out just fine.  It was very windy out the day I made it, so I couldnt use my mig.  I got great penetration and actually blew though the metal with that amperage with the tiny, 10#, 110v inverter on a 20 amp circuit.  The Zinc fumes will get you sick if you inhale them.TA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:Originally Posted by Vince_oBeing a beginer what, why, how come, not to breath the fumes. Im sure its best to avoid all the general fumes that come from us welding, but why do I hear so much about the galvinzed stuff.(
Reply:6011 works well. Forget grinding and use a little whip and a little extra heat. The whip motion burns the galvanize away in front of your puddle. Weld outside and keep your head OUT of the white smoke and you'll be OK.I built a large number of movable fence panels out of 1 1/4" conduit several years ago. I used flux core and found a spool at the LWS that was designed for welding galvanized metal. It was the easiest, smoothest bead I ever put on plated metal but I've forgotten the maker and the wire number. You might check this out with your LWS if you are going to use flux core. You still have to stay out of the smoke.I really HATE welding galvanized metal.
Reply:this is what i found Lincoln wire flux core:--E71T 14 made for galvi and coated metalMiller:-- E71 TGS Hobart: -- "Galvacore"idealarc 250/250 ac-dc tigidealarc 250/250 ac-dc tig #2 used for sticklincoln sp100hh125dual arbor grinder polisher30 yrs of hand tools52 pitch blocks 6p-26prake gauge -pitch gaugeG&D prop repair 918-207-6938Hulbert,okla 74441
Reply:Originally Posted by Vince_oBeing a beginer what, why, how come, not to breath the fumes. Im sure its best to avoid all the general fumes that come from us welding, but why do I hear so much about the galvinzed stuff. I have some 20 ft sticks of galv angle here that I was going to use in building a small tire rack for my spare tires. Maybe Ill rethink this. Then again, I cant find the spare time to build the spare tire rack
Reply:I been welding galvinzed tubing since 1988 used 6011 at the beginning in 1995 switched to self-shielded flux core wire.  I like the ESAB coreshield 15 works the best for me on both hot dipped and coated steels also welds galvinzed to to stainless steel if you watch your voltage settings.  I build dairy setups [ milking parlors holding pens]  have had no problems.  I run a fan to blow away the fumes when i am welding and not a small one
Reply:I just checked Dabit's profile and it shows he was last on here @ 10:06 AM on the 19th. The only response he could have seen was Prop Doctor's 1st and nobody else. Don't you just love it when somebody asks for advice or suggestions, then don't check back in to see the replies from everyone?
Reply:Originally Posted by BistineauI just checked Dabit's profile and it shows he was last on here @ 10:06 AM on the 19th. The only response he could have seen was Prop Doctor's 1st and nobody else. Don't you just love it when somebody asks for advice or suggestions, then don't check back in to see the replies from everyone?
Reply:How about cutting the guy some slack. So he hasn't been back in a couple days. Might have had more pressing matters in life to attend to.I've been guilty of forgetting to go back and read a thread before I wised up and turned on email subscription.PapaLincoln Idealarc 250 (circa 1962)Lincoln Weldpak 155 w/Mig KitLincoln Squarewave TIG 175
Reply:sh*t who cares about him , i learnd a bunch of stuff        thermal arc 252i  -  millermatic 350P -   miller XMT, cp300ts, 30a 22a feeders, buttload of other millers, handfull of lincolns, couple of esabs  -   Hypertherm 1250 G3
Reply:I got curious about the effects of breathing the fumes:http://www.ehow.com/about_5474409_si...l-welding.htmlEver since I read that post about TIG welding and brake cleaner.... ughhhhhhh scary proposition.JoeMiller 140 Autoset (2010)Miller Syncrowave 250 (1996)
Reply:6011 downhand no prep needed.  cold galvanized welded areas after you run a wire brush around to knock off all the little zinc balls that will be stuck to everything.  That thin I would down hand whip it actually that is just weld whip dow or up out of the puddle then come back in.  Sort of the same idea as pulling and releasing the trigger to form a sort of pulsed mig action.  Grinding the galvy off will make your life a lot easier though but this is not standard practice in an inviroment that deals alot with galvanized materials.  you also could get some flux cored wire for your mig cut your shielding cup so it is about 1/4 to 1/2 behind the electrode tip so all the little dingle balls dont get hung up on the tip and sheild and cause shorts to the wire.  This was works really well for production and seems to weld even nicer if you run about 15 psi of co2 with it.  dont ask me why i was just told it one time and tried and saw a real difference in cleanlyness and apperance of weld.www.burdettenetworks.com
Reply:Guys learned a good bit thanks!Learning one rod at a time
Reply:I'd like to thank everyone for their replies.  It gives me alot of information to go on and try what works best for me.  Sorry about not getter back sooner, my dad was rushed to the hospital.  Suddenly welding galv round stuff was not so importaint, I don't always have control of my schedule.I due truely value all of your advise and nothing replaces experiance, and it sounds as if many if not all of you have alot.  Hopefully I will get caught up soon and get back to this project.Thanks again
Reply:I weld alot of galvy and never grind it off. I use 6011, 7018, lincoln 71m, lincoln L56, they all work good for me. As said above just a little more heat and slow down a bit to ensure you burn through the galvy. Galvy sickness is horrible! One time I had major flash burn and galvy sickness at the same time, somebody told me to drink milk to help with the galvy sickness and let me tell ya, being I'm lactose intolerant that just made things worse for me! But i've heard from lots of folks that the milk trick does infact work.Last edited by WelderDude; 11-22-2011 at 08:13 PM.
Reply:Thanks to everyone that responded.  Being my project is small with thin wall tubing I just ground off the galv. My welds looked alot better and was much easier to weld.  Thanks againif you get sick from breathing the fumes drink a glass of milk that always cured me and thats what all of the ol timers around here swear by