Fence building - thin rail to thick post question.

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Have a project. I'm basically a hobby welder. Which welder to use. Lincoln 135 plus or Lincoln 175 plus for .128 galvanized posts to .065 rails. Have to do a lot of it. No pictures yet, because posts going in tomorrow.Vern
Reply:If you have both welders, I always go with the stronger welder and just dial it back on output.  Be sure to start the weld on the thicker piece then bridge to the thinner to avoid burning through.  Don't breathe the fumes from the galvanized. It will make you sick.Miller Syncrowave 350Millermatic 252/ 30A spoolgunMiller Bobcat 225g w/ 3545 spoolgunLincoln PowerArc4000Lincoln 175 Mig  Lincoln 135 Mig Everlast 250EX TigCentury ac/dc 230 amp stickVictor O/AHypertherm 1000 plasma
Reply:The 175 is a 220v machine IIRC. That may limit you to how far you can go to use it to do a fence, unless you are running it from a gen set.  IF you can use 220V where you need to go, it would be my first choice between the two. If you can't get 220V then the 135 will be the only option of the two listed.As said galvy will F you up quick. Grind as much off as you can where you need to weld and stay out of the smoke. A good respirator/mask rated for welding isn't a bad idea if you've got one available. It's a fence, so from your remarks, I assume its all outside. Milk and lots of it helps to combat the symptoms, but it can still hurt you bad..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 choose the 110v machine, run it with .030 E71T-GS or T-11 (NR211) fluxcore wire.  If you choose the 220v machine, you can run either .030 or .035.   The fluxcore wire welds galvanized alot better than solid wire and gas.  Also, since you'll be working outside, with fluxcore you won't be fighting with the wind trying to blow your gas away and won't have to contend with dragging the gas bottle around with you either.Wear a 3M respirator mask with the pink filters and keep your head out of the smoke and you won't have a problem welding the galvanized tube without grinding off the galvi.  This will save you alot of time and work and also be better for the product in the end, since you want the galvanized coating on there to protect against rust.   Chip your slag and brush/wipe the dust off and then spray the weld areas with cold galvanizing compound before priming and painting.   The  cold galvi spray will help protect the welds from rusting.  You can find it at most hardware stores.As far as the thick to thin issue, set your machine for enough heat to weld the thicker metal and then keep the wire/arc focused on the thicker metal and wash it over into the thinner metal.  If you set your machine cold to weld the  thin metal, you won't penetrate and fuse to the thicker one without going very slow trying to heat it up.   Hot and fast is better than slow and cold.   Try to cut your pieces so they have good fit-up and it will be alot easier to weld the thick to thin.   Do your verticals hot and down and you won't be blowing through the thin tube like you may if you go up.  With the fluxcore, concentrate on keeping a very consistent stickout length, as variances in stickout length affect the heat of the arc.  Too short and it gets too hot, too long and it gets too cold.   Also, drag your torch with fluxcore, don't push.Last edited by DesertRider33; 10-29-2009 at 08:49 PM.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:Wow! Thank you. Thank you.My project... http://www.enichesoftware.com/solar/index.htm It's a danger and an attraction for kids. 600 volts at 60 amp system. I'm finishing 715 ft of 4 rail, horse fence 8 ft between posts, to close off the area.The gen is a Sears pickup a week or so away. I've got two fun projects going at once. Plan to build 4 hangers. I'll place 6-21' rails of, slip-in pipe, 42 ft long at once. Tack everything, then go back and weld it.Sorry the generator is so big. It's a big thing to me.Vern
Reply:Interesting project. I'm personally not to keen on how you have the 4x4 braces figured or how the beam sits on the column.It looks like you are toe screwing the 4x4's. There are better ways to do that connection. Side bolt 2x's or do a rest that the 4x's come down onto. There are some inletted timber frame joints that work real well for this.The post caps look a bit flimsy in the lateral direction. I wouldn't trust those light weight plates and a few nails for that. I'd want heavier post caps like the CCQ or CC ones or add fillers to the sides of the beam and run 2x6's up both sides of the post and beam and lag it all together. Usually I prefer the beams lagged and glued straight to the sides of the posts if at all possible.Not seeing all the plans and how this has been designed, I can't make any recommendations, but it's not the way I would do it myself. If it's all designed and signed off by the building inspector or architect you should be good..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:Looks like you're good to go on the generator, that should power either of your machines just fine.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:Thanks again!DWR, I feel your pain, but I had the stupid city to fight. The upgraded post caps were $47 each. I'm trying to streach the buck. The deck holds very little weight. Just solar panels. The 4 x 4 braces will be groved to fit the 2" x 8"s.  Drilled and double lags. The stairs will also give a lot of lateral support, with a 4' x 6' x 6" bolted pad at base. There's no walls.What I like about the generater is it's the smallest one I could find with electric start, under $1k. The only worry is I could not find anything on the wave form. Will it run electronics, like my Powermax 30 plasma?Vern