having blow through issues HELP!!

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ok so im building this bumper and had a hole blow out. 5/32" steel 3/32 7018 rod where two pieces fit together. turned machine down from about 90 amps to about 75 amps. cant get it to fill here is a pic. can anyone give me an idea what I need to do?Lincoln 225 ac (my first machine)farmhand 115vac 70amp mig/fc toymiller aead 200le (my main machine)
Reply:What you are doing won't be easy if your technique and fit up are bad. Keep your arc tight. If you long arc the weld you end up with more heat, and a bigger chance to melt thru. Also you'll need to maintain an even travel speed. Hang out too long in one spot and you'll melt thru. But joints are typically one of the hardest to do, and but joints on thin material is usually even harder..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:If you are welding DC, you may have run up against "arc blow".  You can try moving the ground to a different spot, or you can entwine the welding cables around each other near the work, leaving enough free stinger lead out for you to weld with.  Those steps often defeat arc blow situations.  Another thing to do is to switch over to AC.
Reply:thanks for the info gonna go try the ac machine and see what happensLincoln 225 ac (my first machine)farmhand 115vac 70amp mig/fc toymiller aead 200le (my main machine)
Reply:I'd make short welds, starting at the top, then back step, and skip around a lot. That way the heat won't build up on you.  Attached ImagesDon’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:ok well the hole is filled and there is some spots of undercut here and there. should I use the 6013 low amps to fill and then grind smooth? this is on the side that will show.Lincoln 225 ac (my first machine)farmhand 115vac 70amp mig/fc toymiller aead 200le (my main machine)
Reply:Depends how well you run 6013. I see a lot of guys worried over whether this rod or that is "best" for noncritical projects. Biggest issue in choosing a rod for these projects in my opinion is what rod you can run best. I know a bunch of guys who have issues with slag inclusions running 6013 when learning. Others can run it just fine, but may have issues say running 7018 instead..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:thanks to everyone that posted here is what the hole looks like nowLincoln 225 ac (my first machine)farmhand 115vac 70amp mig/fc toymiller aead 200le (my main machine)
Reply:Too late now but, looks like a tig rig would be good for you to have around.Airco Ac/Dc 300 HeliwelderMillerMatic 200 (stolen)Miller Maxstar 150STLMiller AEAD200LE (welding and generating power) Hobart MIG
Reply:this has been a trial and error project there is a build thread in the projects and pics section. this 5/32 has bee a challenge.Lincoln 225 ac (my first machine)farmhand 115vac 70amp mig/fc toymiller aead 200le (my main machine)
Reply:My first welding project was a rear bumper for my truck.  I had some issues with burn through as well, and most of it was because of poor fitment.  In my "non-professional" opinion, you would be better off to turn your project and make your welds in the flat position when possible.  I've also been told that if you hold a bit more rod angle you can reduce the amount of heat you put into the metal.  This would be in addition to arc length, amperage settings, and travel speed.  I had to back-step quite a bit to reduce warpage.  Good luck and have fun
Reply:wade if you're going to leave those shackles in the pad eyes, you may want to mouse the pins! You can use tie wire, or cut a strand out of some extra wire rope. Attached ImagesDon’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:Thanks CEP, I live in Japan where people know how to leave your stuff alone  I also wrenched the pins down with a large cresent wrench so noone will be stealing them without tools.  They are stainless and I paid a pretty penny for them over here.  I hadn't heard of the mousing.  It is for anti-theft, right?Edit:  Had to look it up.  I hadn't worried about the shackles coming loose before, but I guess it's something I should consider.  Do you think they will come loose if wrenched down tight with a large wrench?Last edited by wade23454; 01-02-2014 at 09:02 AM.
Reply:In my line of work, people's lives depended on rigging! In your case all you'll lose is the shackle, on the job it could be your life. Don’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:I tie wire the shackle pin that holds the uplift chain on my plow. Even cranked down, I've had them back out on occasion..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:Good points about securing the pins.  No matter how tight you may think you have gotten them with tools, the dynamic (and unpredictable) forces that act upon the parts when a load is applied can indeed loosen the pins.For venues such as the Frontier 4X in the pic, loosening by repeated use may be a negligible factor, but in circumstances where they are in use "day in/day out", loosening is nearly guaranteed.
Reply:You want to see shackles, and rigging get rattled around? Hook one of these puppies to something!  Attached ImagesDon’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:I will definitely rethink leaving my shackles on!  Hadn't even considered it, but I agree and understand.