first timer flux core welder. fist project. - JeepForum.com

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post #1 of 38 Old 08-02-2011, 02:54 PM Thread Starter
DoctorTim
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first timer flux core welder. fist project.

i want to make a roof rack with my 90A flux core welder. any tips and tricks i should know about? I've also been practicing on scrap metals and I am having a hard time welding thin sheet metals.

thanks guys


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post #2 of 38 Old 08-02-2011, 03:27 PM
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thin metal will be a little harder with flux core as it burns hotter.I think a roof rack will be a great first project
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post #3 of 38 Old 08-02-2011, 08:23 PM
bigwahini
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My first project for my Handler 140 was a welding cart for it . Got bed frame for $10 and went to town. Came out ok. Some day I plan on a front bumper and trailer.

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post #4 of 38 Old 08-03-2011, 05:42 AM
Apollo21
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I learned stick at sea came home bought a 140 Hobart on ebay for $350 and taught myself MIG with some help from friends. My first and current project is a rear tire carrier.

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post #5 of 38 Old 08-03-2011, 06:59 AM
RedlegWJ
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With flux core, take the sheath off the tip, it won't go through tips quite as fast. Get some welding paste to dip the tip in once in a while too, to help them last longer. If you're having trouble laying a bead, try slowing the wire speed down. Prep-grinding is everything too.

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post #6 of 38 Old 08-03-2011, 07:33 AM
mj40
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mine works great as long as its-new/fresh clean. steel any rust- it'll sputter

if you need to use an extension cord- use a good one..
keep the ground close to your work/weld..
and grind it clean before welding...
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post #7 of 38 Old 08-03-2011, 10:41 AM
dcorn
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Same here, if the metal is dirty at all, it spatters all over the place. I'll have to try taking the sheath off the tip so I can get in some tighter spots. Or I think my HH140 came with a flux tip.

One of my first welding projects was my exhaust, which was pretty tough since it was thin steel. Burned through a bunch. Just keep the heat setting low. I followed the recommended settings on the inside of the welder, and I'm sure you can find the same stuff online for your welder.

Welding thicker stuff is definitely easier to get the hang of because you can go slowers and really focus on the technique.

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post #8 of 38 Old 08-03-2011, 02:39 PM
77351wcj5
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What they said, plus keep all your gaps tight when you fit everything.
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post #9 of 38 Old 08-04-2011, 05:50 AM
dodger889
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Light weight sheet metal will be harder to learn to weld. To keep from burning through use a heavier piece of metal behind it helps a little.

A 89 yj with a 4.0 aw4 sye out of an 92xj. Now the hard part is done time to get it up in the air just a bit. Working on 8.8 with 3.73 and lsd for the rear. and new D30 hp with 3.73 .
For those who have not figured this out I'm old school but can handle the new too.
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post #10 of 38 Old 08-04-2011, 11:06 AM Thread Starter
DoctorTim
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tanks everyone. one last question how to i get perfect 90% angles?

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post #11 of 38 Old 08-04-2011, 12:49 PM
77351wcj5
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Use a square?


Or, if you are talking about tubing, get a tubing notcher off of ebay. Google "ol' joint jigger" and see what you find...
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post #12 of 38 Old 08-05-2011, 02:25 PM
Jamesbbh
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For right angles with tube I use a right angle Jig made for carpentry work, it's just two clamps that face each other at a perfect angle.
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post #13 of 38 Old 08-05-2011, 02:28 PM
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One of my fist projects- a bracket to hold the CO2/argon tank on a trailer. Here is the right angle Jig





Before you tackle an actual project though you should look into making something like this. This was the second thing other than random scraps I ever welded. It teaches you a lot about angles/joints and just welding in general. Good luck man!

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post #14 of 38 Old 08-05-2011, 04:24 PM Thread Starter
DoctorTim
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first project. what you guys think? i keep getting lots of splatter even if im cleaning the metal beforehand. I've also tried limiting the wire feed but i still get splatter. I also regularly burnt through the thin metal but with the thicker L channel pieces i think i did really good for a first project.
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post #15 of 38 Old 08-05-2011, 05:53 PM
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I've got the same welder, and am well aware of what it can and can't do. I bought it for a few simple projects and it's worked fine, but... I ditched the wire that came with it and bought some nice Hobart flux core. It made a huge difference for me. If you can rule out cheap wire, then it will be easier to practice welding. Otherwise it's hard to tell whether it's inexperience or the wire causing your issues.

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