Need info about tig welding thin metal

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I have a Miller Maxstar 150 STL 110-220V. AMP range is 15-150. I have it wired to 220. It has a thumb control that can be used to adjust the amperes on the fly. This machine is only used for tig welding. I'm currently (always) using a 3/32 2% tungsten with 100% pure argon.My step son and I have started a rat rod project and I want to replace the dash. Now since the dash I want to use has to be cut down (shortened) take some from the middle and I need to be able to weld it back together. So now for the question; what equipment do I need to use to weld on the dash? It is probably no thicker than 18ga. Very likely thinner. It's from a 59 Chevy Impala. I have welded (tig) some 16ga and maybe some 18ga in years past. All of my past welding on this thickness would have been Stainless Steel. I have tig welded some mild steel but never anything thinner than 14ga. Tungsten size? Filler Rod size?Brand or grade of filler rod?AMP range?Any information would be appreciated.Thanks,WadeHave A Big Time! Wade
Reply:Set the amps to about 65. Use .45 or 1/16 filler 70s2. And a #5,6 or 7 cup with gas lense and 1/16 tungsten of your choice I like thoriated. 16 cfh or less depending on stick out. You need the fit up to be good on that thin if metal. How do your welds look now?
Reply:Originally Posted by motolife313Set the amps to about 65. Use .45 or 1/16 filler 70s2. And a #5,6 or 7 cup with gas lense and 1/16 tungsten of your choice I like thoriated. 16 cfh or less depending on stick out. You need the fit up to be good on that thin if metal. How do your welds look now?
Reply:Is the dashboard flat?...zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:A good sharp needle pointed 3/32" tungsten will work. 1/16" tungsten is just a bit easier to control the puddle with some times. Nice thing about steel is that if you get your amps dialed in right, you really don't need a remote. If you know how to use one that can make things a bit easier, but it's not required at this thickness. As mentioned fit up will be key. 1/16" filler would be on the large side in my book. It's doable, but tough when the base material matches the filler size. .045 filler or .035/.030 mig wire would work. You can also use the old copper backing trick body guys do with mig to help support the puddle if you have issues with something this thin.but with 16ga I have to really start paying closer attention.
Reply:Ya I've tried e3 but I like the red better. 1/16 will have a better sharper arc at those low amps. You will probably only be using 45 amps depending on what kind of joint your welding. But it doesn't talorate being nicked by the puddle at all I've found.
Reply:Originally Posted by zapsterIs the dashboard flat?...zap!
Reply:I like to run hotter than on the cold side, as I have seen what happens with cold welds. And I really like to keep the tungsten sharp. Since I regulate tungsten at work, I find my self getting on some guys about their use of such. I tell'em, learn how to weld and you won't burn off the tip as much. I have a lot of "grinders" not welders. LOL, maybe one of these days they'll pick it up. I'm sure glad they are not depended on for something real serious!Have A Big Time! Wade
Reply:I had rather not use the Dial as it is very aggravating for me to get my hand in a good position to make good use of it. I appreciate the information, just ordered me a 1/16" set up for my torch. I'm assuming from DSW's info, I an probably use some .035 wire from my wire welder spool?Have A Big Time! Wade
Reply:If you got a couple extra bucks you could just buy a pound of .035 36 inch tig filler. It would be straight lol
Reply:Originally Posted by motolife313If you got a couple extra bucks you could just buy a pound of .035 36 inch tig filler. It would be straight lol
Reply:Not really sure what you mean but you can buy .035 and .045 to fix a crack in ss fryer tank. I'm not really a stainless wiz but I think er312 will take care of most all stainless steel. Hopefully someone will correct me if I'm wrong?
Reply:Originally Posted by motolife313Not really sure what you mean but you can buy .035 and .045 to fix a crack in ss fryer tank. I'm not really a stainless wiz but I think er312 will take care of most all stainless steel. Hopefully someone will correct me if I'm wrong?