Tigging nice beads on thin mild steel sheet

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Any suggestions for improving weld appearance for thin sheet (=<22 ga)?I find I get a good bead going and get and inch or so then I'm enough out of position that it gets difficult to keep good angles torch and filler so stop to reposition piece then it seems dificult to get the same heat and bead profile going again. I find it a lot easier to get nice looking welds on 1/8 inch plus material.Also I end up too often welding with a contaminated electrode, was just thinking, I will grind 10 up and have them ready to change so I don't need to stop and go to the grinder then come back and get set up. If it's easier to just switch to a clean electrode I won't try to keep going if the tungsten is at all messed.1/16 goldband, #6 gas lens, 50 amps @ 20 hz pulse, peddal bout mid point, 1/16 S70 filler.Looking into new glass too, the old HF style helmet is not as clear a view as it could be and I'v flashed myself a number of times by welding in places the sensore won't pick up.Thanks for the ideas, maybe it's just more hood time, each pipe looks a little beter than the last, still it would make me happy to improve the look of the welds. Attached ImagesLast edited by Timberwolf; 07-13-2009 at 07:56 AM.Lincoln PT185 TIGLincoln 175 MIGLincoln 240 amp AC StickLind Needle Arc plasma welderPlasma cutter, soon???
Reply:Get yourself some finer filler wire, the heat required to melt 1/16 filler is more than needed to weld 22swg. As long as your fit up is good it will make your life MUCH easier and the welds will be much smaller and neater. You can feed out some 0.8mm MIG wire and straighten it (clamp one end in a vice the other in a drill chuck and with it under some tension give it a spin) or you can buy straight lengths in 1.0mm (0.040")
Reply:You can feed out some 0.8mm MIG wire and straighten it (clamp one end in a vice the other in a drill chuck and with it under some tension give it a spin)
Reply:You'll find you need less amps with the finer filler. Not too much tension and don't go too mad with the drill or you'll snap the filler. Keep the 1/16 to hand for any holes that need filling/gaps that need bridging
Reply:Hotrodder, Thanks for the tip on straightening the mig wire. I've never had much luck getting any decently straight to play with. I've got goobs of SS mig wire, but hand "straightening", if you can call it straight, has never worked well.
Reply:OK, I'll bite. You making Hot Rod Skateboards?  Putting them on Hang Gliders? Toboggans?
Reply:Lumberjack competitions. It sure does not get the following of Nascar but none the less it gets very competative.Lincoln PT185 TIGLincoln 175 MIGLincoln 240 amp AC StickLind Needle Arc plasma welderPlasma cutter, soon???
Reply:Originally Posted by TimberwolfLumberjack competitions. It sure does not get the following of Nascar but none the less it gets very competative.
Reply:A bit off topic but I am curious about your process you use to make those exhaust. They are very nice. Do you start out with sheet and roll to different diameters or do you buy tons of prebent mandrel diameters? Any chance of some more pics from different angles? I would love to do something like that for my lawnmower.
Reply:Actually it's much bigger in the US and most saws I build race in US.Lincoln PT185 TIGLincoln 175 MIGLincoln 240 amp AC StickLind Needle Arc plasma welderPlasma cutter, soon???
Reply:Artworksmetal:You might enjoy this thread by Timberwolf:http://weldingweb.com/vbb/showthread.php?t=239019-11-2001......We Will Never ForgetRetired desk jockey. Hobby weldor with a little training. Craftsman O/A---Flat, Vert, Ovhd, Horz. Miller Syncrowave 250
Reply:Only had .023 wire so spun two together and made 10 2 foot filler rods. Got to say it works well, but is going to take a little getting accustomed to. Likely dropped 10-15 amps and bead narrowed up a good 1/16 of an inch.I think I will order some .035 or .040 tig filler though next time I find something I need to order. Attached ImagesLincoln PT185 TIGLincoln 175 MIGLincoln 240 amp AC StickLind Needle Arc plasma welderPlasma cutter, soon???
Reply:Originally Posted by Craig in DenverArtworksmetal:You might enjoy this thread by Timberwolf:http://weldingweb.com/vbb/showthread.php?t=23901
Reply:A tuned pipe on a two stroke motor works a bit like a supercharger and allows more fuel and air to be packed in and burnt each stroke. Pipes are easy gains of 20-40%. For racing I would be pushing horsepower about 3 times stock for gas engines and 5 times for nitro/methanol.Practical, not at all, but a lot of fun.Lincoln PT185 TIGLincoln 175 MIGLincoln 240 amp AC StickLind Needle Arc plasma welderPlasma cutter, soon???
Reply:How do you calculate the cuts in your sheet so well? Do you just eyeball it or is there some sort of formula for bends and radii?
Reply:Originally Posted by TimberwolfPractical, not at all, but a lot of fun.
Reply:I started out doing the math long hand, then made and xls spread sheet, now I mostly use comercial software as it prints the sections directly and is a lot faster. There are a couple cone layout demos that can be downloaded or are pretty low cost. Getting the cones to lay out into a pipe in 3 dimentions though boils down to getting the knack for it, fit it up with paper then test fit with metal and lastly weld. Attached ImagesLincoln PT185 TIGLincoln 175 MIGLincoln 240 amp AC StickLind Needle Arc plasma welderPlasma cutter, soon???
Reply:A number of years ago I helped a friend build a Yamaha Twin Jet 100cc motorcycle engine into a racin' chain saw.  That was a gnarly, sawdust spewin' unit!!Rex
Reply:Thanks for the info and pics. Is there any particular software that you can recommend? The pics speak a million words. BTW I have that same ultrasonic cleaner. Works quite well to clean small parts like injectors and such.
Reply:Yep cleaner works well, but the plastic lid on mine cracked, likely related to using some solvents in it.Cone Layout (free demo works beyond 21 days but delays on opening 1 second for every day $40-$50 to register) http://www.pulserate.com/Also Mota Demo has some basic tools, but need to buy it @ $250 from Australia to get full toolshttp://www.iwt.com.au/MOTA.HTMThere is Sheet Lightning 5 as well, demo functions but no outputs $100 to $150 for license.Last edited by Timberwolf; 07-15-2009 at 07:16 AM.Lincoln PT185 TIGLincoln 175 MIGLincoln 240 amp AC StickLind Needle Arc plasma welderPlasma cutter, soon???