Welding pressed steel pipe caps

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This is my problem.  I have 4" pipe fence posts .25wall and need to weld pressed steel caps to seal the posts.  Every attempt leads to burn holes in the lighter weight caps.  I am using a Lincoln GXT and not very experienced.  Any help is greatly appreciated.
Reply:What rod and rod size are you trying to use? How thick are the caps? Size your rod for the cap not the post. Just guessing on the cap but I'd start with a 3/32 6013 rod if I had to do it with stick. If the cap is really thin 1/16 6013 rod is available.
Reply:That is a huge post.  Practice--your applying too much heat to the cap.  You need to get the puddle started on the 1/4" wall pipe, then wash/brush the puddle onto the edge of the cap.  You are concentrating too much heat on the cap, hence burn through.  You could always "punt" and glue the caps on.  Construction adhesives, and jb weld work.  As long as you are through welding around them glue works.  I glue caps on frequently if they are going to be out of the way.  Like a all fence.
Reply:Maybe it only needs to be tacked on to be good enough for its purpose? when tacking it start the puddle on the thick part and move it over onto the thinner part but with just enough to fuse it together. Yea tapwelder got the idea too. are the fence posts allready put into the ground?Last edited by Doug247; 07-31-2007 at 12:37 AM.Nothing Ever Got Done By Quitting, Never Give Up.
Reply:Yes, the posts are already set in the ground and are used with barb wire fencing.  The 'glue' tip sounds interesting.
Reply:If all you are wanting to do is hold the cap on.  Take a torch and a brazing rod, and braze it on.  You don't need to go all the way around.  Just a 1/2" tack on each side is a plenty.I'm a Lover, Fighter, Wild horse Rider, and a pretty good welding man......
Reply:I use to braze my caps on.  My goal was to get the filler to go underneath the cap leaving the edges undamaged.  However, if the gap is too large, then capillary action does take place and gravity prevails.  Thus, I started gluing.    What type finish do you have on your posts?  galvanized, paint, powder coat...