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Unread 08-02-2011, 02:54 PM   #1
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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Unread 08-02-2011, 03:27 PM   #2
Machinist
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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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Unread 08-02-2011, 08:23 PM   #3
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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Unread 08-03-2011, 05:42 AM   #4
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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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Unread 08-03-2011, 06:59 AM   #5
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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Unread 08-03-2011, 07:33 AM   #6
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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Unread 08-03-2011, 10:41 AM   #7
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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Unread 08-03-2011, 02:39 PM   #8
77351wcj5
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What they said, plus keep all your gaps tight when you fit everything.
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Unread 08-04-2011, 05:50 AM   #9
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.
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Unread 08-04-2011, 11:06 AM   #10
DoctorTim
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tanks everyone. one last question how to i get perfect 90% angles?
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Unread 08-04-2011, 12:49 PM   #11
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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Unread 08-05-2011, 02:25 PM   #12
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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Unread 08-05-2011, 02:28 PM   #13
Jamesbbh
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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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Unread 08-05-2011, 04:24 PM   #14
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.
photo0755.jpg   photo0756.jpg   photo0758.jpg   photo0759.jpg  
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Unread 08-05-2011, 05:53 PM   #15
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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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