critique my welds

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I've been welding for awhile, but mostly on 3/16" and smaller stuff. I'm working on an axle swap in my Jeep and using 1/4" brackets. The welder I'm using is a Hobart handler 110v machine with flux core .035" wire. I know that 1/4" is the limit for a 110 machine even with flux, but I wanted some opinions on how my welds look. They seem to have good penetration to me, but I know my technique could improve a bit. I usually drag the puddle with the torch at a slight angle, welder settings were voltage on 4 of 4, wire speed 25-30 of 100. Are my welds okay, or should I cut them out and redo them? The pictures were taken after I quickly ran a wire brush over them by hand to clean the flux off.This picture is .120 wall DOM tube welded to the frame. It was in a very awkward position, so I had to start a new bead a couple of times over the length.Any input would be appreciated. Redoing them wouldn't be hard as I have a powermax 45 plasma cutter I could gouge them out with and start fresh, but from my (amateur) perspective they look okay to use as-is.
Reply:I have been keeping my eye out for a good deal on a 220v mig as I know it would make this project much easier and I'd be able to weld much faster, but I haven't found one in my limited budget yet.
Reply:1/8" is the real practical limit of small 110v machines even with FC wire, despite what the manufacturers may say in their literature. Even then you can only do short beads on 1/8". The 1st bead shows the lack of heat from what I can see.  Small migs are especially prone to making "good" looking welds that are cold and are not well tied into the base material. That's clear to me in the 1st pict. This is especially true at the bottom of the welded area. I seriously doubt you have anywhere neer the penetration you think you have. The 2nd is just plain ugly, and #3 isn't far behind. The 1st and  and 4th show you need to work on your consistancy.Vehicle mods like these are NOT learning projects or begginer projects. I hope this is strictly for off road use and isn't your daily driver.  To do mods like this you need to at least be able to make code quality welds in all positions as well as in restricted spaces. Your welds show you aren't anywhere near close in this. ( the welds aren't bad for someone learning, but they have a long way to go before they are up to this sort of project.)Welding things to the frame is definately a no no. Most manufacturers specifically state you are not to weld to frames. Many are high tensile alloys or heat treated and require special welding requirements. As far as cutting these out, I'd be afraid you will do even more damage than you already may have done in some cases. I doubt you have the skills to cut these out cleanly and not damage the surounding material.As far as the 220v welder, it won't just make the project easier, it's absolutly nessesary to get quality welds on material this thick.Oh and in the future please resize the picts 1st. It makes it easier to read your text..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:They are not too too bad, I would clean them up real good with a wire wheel and cap it with 2 passes, one beside each other covering the single pass you got there and slow down a little bit. More heat.Last edited by Dantheman; 07-26-2011 at 06:01 PM.
Reply:Oh god..Not another one.....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:Originally Posted by DanthemanThey are not too too bad, I would clean them up real good with a wire wheel and cap it with 2 passes, one beside each other covering the single pass you got there and slow down a little bit. More heat.
Reply:Thanks for the input DSW. I'm looking at a Miller 180 used for a decent price or getting a new Miller 211. Is there a significant difference in the two as far as capabilities? As to removing the existing welds I have way more experience at that then welding 1/4", so I'm not worried about taking them off without effecting the material underneath. If the welds are cold they should cut off very easily without damaging the surrounding material. Using either the plasma cutter to gouge them out or a cut-off wheel to split the weld and then clean up the base material using a grinding wheel and then flap disc. I definitely won't weld over a cold weld in an attempt to fix it. If cutting them out isn't an option, how would you recommend fixing them? Sorry about the pics -I had resized them, but I'm on a computer with a fairly large screen that they fit on nicely. I'll make them smaller next time.
Reply:Small welder=small, multi pass welds. That should have been done in about three smaller passes and as hot as it can burn.Two turn tables and a microphone.
Reply:Both the MM180 and the MM211 are nice machines when running on 230v power. The MM211 has more top end power and the ability to do what your current machine can when run on 110v power. It's a toss up. Your current machine plus the MM180 would do almost the same things you can do with the MM211.Don't be afraid of some of the older machines either, the MM185, MM200, MM250, MM251 are all good machines with at least as much power as the MM211 has and then some in the case of the 250-251's..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:Thanks for the response. I've been looking for a used welder for awhile and not much has come up. Looks like I'm spending tomorrow cutting out weld... and looking for a good solid larger machine.
Reply:I like to use a CL search engine like Searchtempest to look at other CL listings easily. I usually use the key word "welder" and search the list manually from there. I usually look up to 50 miles for most things. I've picked up some real deals that were listed on CL west of my location that I might not have spotted otherwise..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:I've found a couple of used welders on craigslist within an hour of me, but they are all priced close to what a new 211 costs or one (250x) was priced at $500 more than a new 211. Strongly considering getting a new 211 and selling my current 110v machine to recoup some of the cost.
Reply:211 is a good machine for what you're wanting to do.  If you can swing it cash wise that'd be the way I'd go
Reply:Just waiting for a guy to pick up some stuff I'm selling (should be within the hour) and I'll be ordering a new 211 tonight. I've got a pile of scrap to practice on, so hopefully with a few days put into practice I'll be able to get some decent welds with it.
Reply:"They seem to have good penetration to me........." How do you check for penetration from looking at a weld??......Macro etching the material!!.....Please look up weld penetration. And fusion...What i see is fusion on the toes,there is a lot of flux left on the toes so i cant see the whole bead, undercutting, and inconsistent beads.I forgot how to change this.
Reply:Too many people watching extreme 4 x4 on Saturdays. This is the danger it gets people into. I see now they only show mostly tack welding on these shows. What joke shows.T.J.www.tjsperformance.comDynasty 300 DXHTP 240HTP Microcut 380Hyperthem 85JD2 Hyd Bender and HF Hyd Ring Roller all in one =(Frankenbender)Bpt. Mill/DRO4' x 8' CNC Plasma TableInstagram: tjsperformanceYT: TJS Welding and Fabrication
Reply:I for one think the op is going to make a great hobby welder.  he has demonstrated the rare trait of being teachable.  It is hard to be told you laid down trash welds that need to be cut out.  You handled that in spades.the 211 is a fine machine.  when you get som more cheese you can order a spool gun and be set for a long time.As for the gouging, take it slowly.  don't try and take the whole weld out at a time.  nibble at it and when you get close use a hammer and pop the weld by hitting the bracket.  It is better to eat into the bracket some rather than the axle or frame.  The bracket can be replaced cheaper should you have to replace something.  most of the time you can save them both.when you get your new machine get .030 hard wire.  even though your machine may be able to push .035 hard wire, .030 is better for the size machine you will have.
Reply:I've cut numerous brackets off before and have that down pretty well. This isn't the first welding I've done, just the first using 1/4" to thicker axle tubes. I really wasn't sure if the machine was capable, but I've done thinner brackets on smaller axles (3x) and had much better welds -hence why I posted up these. I believe I can let this thread die now... I suck using a 110v machine for something it shouldn't be doing. Hopefully when I get my 211 in and get a few days practice in, I'll have some better looking welds
Reply:i would suggest a lincoln 180c mig welder... they run like $700also look at the hobart handler 187, Rural King sells them for $600, Tractor Supply Company just had a sale on the HH187's for $550, dont know if theyre still on sale or not..if i were messing with 4x4's and doing a fair amount of welding on trucks and hotrods and were more than likely going to do it pretty much the rest of my career i would go ahead and get a hobart ironman 230.. you would never have an undersized machine with a 250amp mig welder at home.tackleexperts.comwww.necessityjigs.comhttps://www.facebook.com/groups/mach...dingequipment/
Reply:Mattamd_xp,If your budget is limited, why don't you buy a used "buzz box", like an old Lincoln tomb stone arc welder?  I see 'em all day long for $150ish, plus a "good" weld is more obvious with stick vs wire-feed.Lincoln SA 200Esab Caddy 160Thermal Arc 201TSMiller Dialarc HFI don't like making plans for the day because then the word "premeditated" gets thrown around the courtroom....
Reply:Originally Posted by dubl_tMattamd_xp,If your budget is limited, why don't you buy a used "buzz box", like an old Lincoln tomb stone arc welder?  I see 'em all day long for $150ish, plus a "good" weld is more obvious with stick vs wire-feed.
Reply:Picked up a miller 211 in early August and ran a bunch of practice wire through it. Thought I would post up some progress I've made
Reply:Looks like you are getting there..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:Have to pick up more wire before I can do anything else. Burned through a whole spool