what is the best way to weld this?

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I have to duplicate the rail in the photo.   I have two to rails to fab. It is a simple rail--all parts are prefabbed. The parts are cast iron.  There will be cast to cast and cast to steel joints. What is the best most efficient way to weld this part?  I think stick.  I'll probably build it outside since I don't antipate much fab time.What rod?  Any precautions? Attached ImagesLast edited by tapwelder; 06-01-2007 at 03:14 AM.
Reply:Could you braize it?DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:It's not structural.  The welds just keep the stuff on there.  I MIG this stuff all the time.If you do SMAW, any basic rod will work, but I use 7018 for all-position bead appearance and ductility.
Reply:This will sound weird but I'm doing a good bit of almost exactly that lately and I TIG it with 309L filler (indoors).  Right now I'm working on a set of window well windows with aluminum castings in an aluminum frame -- 6xxx Al with 4043 filler (and I'll post pics when they're done    (And man that aluminum is a pain but it makes steel seem like child's play when I switch back to steel.   )I'm told that the nickel content in the 309 allows a bit of stretch to help avoid cracking the cast iron pieces.  That's what I'm told -- I'm not any metalurgist.  I don't even know for sure if 309 has a lot of nickel in it.  It works so good to go for me.Another something I've been told -- but I've never tried -- is silicon bronze to TIG braze it.  I might try that next time just to see how it works out.Whatever process you choose -- make sure to post pics.  That will be one nice looking rail.  Where do you get your castings and parts?Last edited by phila.renewal; 06-01-2007 at 08:53 AM.Favorite right now is a Miller Syncro 200.Tons of tools and I blame at least one of them when things don't go right.
Reply:Thanks I use 6013 and mig for lots of cast stuff, like mailboxes and collars and shoes.  However, since this is over head, I want to do it right.  The occasional crack could be disasterous.Those are all parts from www.kingmetals.com.  My rail will look exactly like that one--not too exiting.  It is on the same house. The client just completed an addition.
Reply:If its cast iron I would use ni-rod. Cast wire works really well also but the wire is very "pricey". I certainly would not do it with 6013 or 7018. But that is just me. They both may work just fine. My opinion ni-rod is the way to go.
Reply:Originally Posted by tapwelderMy rail will look exactly like that one--not too exiting.