Something odd happened on the weekend

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I went to do some welding with my 15 year old stick welder and instead of the rod sparking, the earth lead sparked. Never happened before. I disconnected everything and started again and it was fine. What gives?And while I'm at it, what are some basic safety rules I should be following?I've never done a welding course and just do stuff around the house.I do have a cutout switch on my electrical switchboard - most new switchboards in Australia have them. If there's a short in any appliance, the power is cut off immediately. Of course, when I'm welding thicker, metal and have the amps turned up, the kill switch trips often. In fact it trips so often that I avoid jobs that require heavier steel.ScottLast edited by scott brunsdon; 11-27-2005 at 08:38 PM.
Reply:I went to do some welding with my 15 year old stick welder and instead of the rod sparking, the earth lead sparked. Never happened before. I disconnected everything and started again and it was fine. What gives?
Reply:Given I mostly use steel that is either second hand or that has been sitting around in my backyard for years, it's never clean metal. I always clean the weld site, but never where I'm clamping. Mystery solved. It's odd, though, that it's the first time it has ever happened. And that made me think of safety issues. People who do stuff at home would do things that would horrify a professional. Yesterday I was welding in thongs. No, not that sort of thong - 'thongs' in Australia are things you wear on your feet to the beach. They're basically a piece of rubber with a strap. I get the odd bit of hot metal dropping on my feet, but nothing more than that. I suspect that I should start wearing shoes.    What else should I do? Should I wear gloves? Scott
Reply:Gald you explained that "thong" issue!!! Here in Kalifornia, when someone says they were welding in a thing, good chance they were-----------well ya never know. Anyway. Many safety lessons generally end up being self taught.  Gloves or at least a glove on the left hand would be good. Sooner or later your gonna reach over and grap the hot metal. When that happens, without a glove, it's major. More than just a burn.
Reply:I'll just add my $.02.   Try to avoid wearing frayed clothing.   This past summer, I was mig welding a fire ring and realized my nether regions were getting a bit toasty.   I lifted my helment to find my favorite pair of shorts, thread bare and frayed that they were (and with me in them), were fully engulfed in flames.   Fortunately, I was able to stop, drop and roll myself out of trouble, but a valuable lesson was learned.There are no small projects
Reply:I took on board your comment about 'frayed clothing', Imagineer. But sadly I've persisted with wearing 'thongs' - on my feet - while welding.It could be time to rethink this.I'm building some stairs. Only 4 treads and 4 risers. They're all in one piece bent out of 3mm checkplate steel 1200mm (4 feet) wide.Fairly heavy - a 2 man lift.I had them balanced precariously while I was welding a riser to the back of them.They fell.On my toe.
Reply:Damn,dude,sorry to hear that! Are you seriously hurt?
Reply:Not really.The fact that it bled out the side of the toe was probably good. I iced it straightaway.I'll still get a black nail out of it. No sign of any infection yet, which is great. Last time I did that to a toe (moving house and dropped a cupboard onto it) I decided to relieve the pressure and let the gunk out by drilling a hole in the nail. I thought the nail would offer more resistance than it did and pressed a bit too hard. Went right through. I won't do that this time. I'm a fast learner sometimes.And I'll wear boots when working with heavy steel from now on. Of course, it will be a couple of weeks till I can get boots on. Luckily it's summer down here and can wear thongs most of the time. ScottOh, and Sandy, I've been wearing a glove on my left hand, too.
Reply:Originally Posted by scott brunsdonLast time I did that to a toe (moving house and dropped a cupboard onto it) I decided to relieve the pressure and let the gunk out by drilling a hole in the nail. I thought the nail would offer more resistance than it did and pressed a bit too hard. Went right through.
Reply:I have to tell y'all a story about our neighbors where I grew up.  I lived just down the dirt road from a family with 19 children (all biological, none step or adopted).  As soon as they were old enough to pick up a chain saw, they went into the family business of pulp wood.  One day, one of the older boys got his thumb crushed and another brother offered to relieve the pressure with a paneling nail.  I guess there were some un-resolved issues between them, but instead of relieving the pressure, the other brother nailed the first brother's thumb to a big stump and ran off.  That boy stood there with his thiumb nailed to a stump for quite a while before his other family members heard him yelling.  Needless to say, a big fight eventually ensued.I would use their real names, but like I said there are 19 siblings, so, I'd rather not start a feud with that kind of odds.  I know it's sick, and really mean, but I still laugh about that every time I see those brothers.  The lesson to be learned here, Scott, is make sure you square things with anyone who you are trusting to punch a hole in your toenail.Smithboy...if it ain't broke, you ain't tryin'.
Reply:Kinda late on the reply but Ill throw this out anyways. If you ever have a blood blister under the bail, you can use a drill bit, but for god sakes dont chuck it up  in a drill and just start making holes in yourself.  Take a small,SHARP bit and hold it between your thumb and forefinger. Twist back and forth while slowly applying pressure. You can never accidently drill too deep, and your always in control of every variable.
Reply:By the look of my toe, I'll be getting a little drill bit or a paperclip out by the weekend.The stairs looked good, though. I sent them off to the galvaniser yesterday and they should come back next week.Next job is a gate. At least it won't be as heavy if I drop it.I might have to start welding at night when it's cool enough to wear boots.Scott
Reply:Scott, there are some basics: 1] Gravity is a fairly reliable effect. 2] Steel ALWAYS has the right of way! 3] NEVER put the parts that bleed in harms way. My pilot buddy argues with #1, says there is no such thing as gravity;" the earth sucks".    I hope you get better soon.