BBQ repair question

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I am very new to welding and need to repair a BBQ.  I want to weld a piece to close off where a rotisserie goes on both sides of the lid.  It is a standard (not stainless) BBQ and I'm not sure what type of metal or how to prep it for welding.  I am using a 110v mig/flux welder.Any help would be great.Nick
Reply:First you have to find or figure out what kind of metal you have there Nick.I've seen metal BBQs or parts thereof in plain steel, stainless steel, stamped aluminum, cast aluminum,  cast iron, chrome-plated steel, etc.  The best laid schemes ... Gang oft agley ...
Reply:Be easier to make a Upright Drum Smoker.Most of the newer ones (past 20 years or so) are made from cast aluminum.  Unless it's a sheetmetal one.Post up a pic of what your trying to do, several here might help identify the material.MarkI haven't always been a nurse........Craftsman 12"x36" LatheEnco G-30B MillHobart Handler 175Lincoln WeldandPower 225 AC/DC G-7 CV/CCAdd a Foot Pedal to a Harbor Freight Chicago Electric 165A DC TIG PapaLion's Gate Build
Reply:I've scrapped a bunch of grills that were cast alum. Most are covered in heavy grease. Before you can probably even try to weld it you are going to need to do a heavy cleaning most likely. I seriously doubt you'll end up with much luck with the 110v mig and alum however.You may be able to just fab a plate to fix the problem and bolt it to the existing part of the grill..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 a magnet will stick to it it is most likely mild steel. wash off thegrease where you want to weld. grind it clean. if it is over 1/8 thick, heat it up with a torch. post a foto.if it isnt mild steel, use some nuts and bolts to attach your patch.
Reply:As far as repairing a commercial grill unless it is stainless it will be cast Al and you will not have much luck welding it unless you get fancy with a TIG. A bolted on patch is pretty much your only option.I second the UDS idea, "Ugly Drum Smoker" cost me about $30 and some time. Now I can do real BBQ. This is a perfect project for a 110V welder:http://www.thesmokering.com/forum/viewtopic.php?t=13224 I used a jet fuel drum that I got for $5, 16 gauge for my deflector, expanded metal for the cooking grate and fridge magnets to control the air intake. All you need is a jigsaw and your little welder.