Welding Hex Rod

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Hi all,I'm new to the forum, and pretty new to welding in general. I recently got a great deal on a batch of 3/4" galvanized hex rod, 18" lengths. I'm planning to use it for some upcoming projects, but have a couple of questions. I understand the health risks of welding galvanized steel, and plan to remove the galvanization prior to welding. I'm wondering the best way to prep hex rod for the various weld joints? I tried to google it, but wasn't able to find any information. For example, a 90 degree joint would result in only a small area of contact without some preparation cuts (1/3 of the surface area). Should I cut the end of the rod in half, giving a flat section for greater surface areaMy projects will be mostly related to woodturning - tools, tailstock riser and similar. I'm planning to use the rod as a rigid frame, then clad the structure in 1/8" steel sheet. I've been using a Lincoln Weld-Pak 100 flux-core welder so far, and just bought an oxy-acetylene torch set but have yet to delve into that. Thanks in advance for any information you can provide. Best regards,Lee
Reply:Originally Posted by leekoHi all,I'm new to the forum, and pretty new to welding in general. I recently got a great deal on a batch of 3/4" galvanized hex rod, 18" lengths. I'm planning to use it for some upcoming projects, but have a couple of questions. I understand the health risks of welding galvanized steel, and plan to remove the galvanization prior to welding. I'm wondering the best way to prep hex rod for the various weld joints? I tried to google it, but wasn't able to find any information. For example, a 90 degree joint would result in only a small area of contact without some preparation cuts (1/3 of the surface area). Should I cut the end of the rod in half, giving a flat section for greater surface areaMy projects will be mostly related to woodturning - tools, tailstock riser and similar. I'm planning to use the rod as a rigid frame, then clad the structure in 1/8" steel sheet. I've been using a Lincoln Weld-Pak 100 flux-core welder so far, and just bought an oxy-acetylene torch set but have yet to delve into that. Thanks in advance for any information you can provide. Best regards,Lee
Reply:Galvanize is zinc.  It is an element that the body uses to some extent. The body will get sick if it gets to much. If you get zinc poison imedeatly drink milk and it will cure your sickness.  its not considered extremely dangerous. just very uncomfortable. Look it up on Wikipedia.  Mac
Reply:If I understand what you're asking, could you not treat the joint between the flat face and the hex face like a bevel and fill it up with bead?Everlast PA160-STH... and that's about it!
Reply:you can grind the galv off, or burn it off with the oa set..
Reply:Burning it off will create zinc fumes, which the OP is trying to avoid. Muriatic acid, diluted 50/50 with water, will remove galvanizing effortlessly. Just rinse well and dry immediately, or it will rust.JohnA few weldersA lot of hammersA whole lot of C-clamps
Reply:muriatic doesnt create  fumes?and perhaps you put too much stock in effortlessness..i can pissss effortlessly in my pants but its not  necessarily a desirable outcome..Last edited by weldbead; 06-27-2013 at 06:13 AM.
Reply:Thanks for all the responses. Joshua, you hit the nail on the head - I'll fill up the gap with bead. It'll be a pretty big bevel though - would that weaken the joint compared with a smaller bevel? Weldbead - you should probably see a doctor about that Lee
Reply:Can you not miter cut the ends to your desired angle? That would by far look the best.Lincoln precision TIG 275Millermatic 140 MIG
Reply:Originally Posted by leekoHi all,I'm new to the forum, and pretty new to welding in general. I've been using a Lincoln Weld-Pak 100 flux-core welder so far, and just bought an oxy-acetylene torch set but have yet to delve into that. Thanks in advance for any information you can provide. Best regards,Lee
Reply:without commenthttp://www.cdc.gov/niosh/docs/81-123/pdfs/0675.pdfhttp://www.ncbi.nlm.nih.gov/pmc/articles/PMC2796768/Hey~!! It's a hobby. It's not supposed to make sense~!!