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first timer flux core welder. fist project.

10K views 37 replies 20 participants last post by  Bobbyreb97 
#1 ·
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
 
#4 ·
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.
 
#5 ·
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.
 
#7 ·
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.
 
#9 ·
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.
 
#13 ·
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!

 
#14 ·
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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#21 ·
It looks like hammered **** but it's suppose to right now till you get a lot of practice under your belt then things will look much better.

My first project was with thicker metal and had lots of splatter and piss poor beads but it's still holding together.
 
#15 ·
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.
 
#16 ·
Yeah the HF wire sucks and doesn't burn well. The penetration stinks. The Hobart wire gives me much better heat and penetration so i can usually speed up the wire instead of going so slow waiting for good penetration.
 
#19 ·
lincoln flux cored wire works good too. For welding the thinner materials, I usually go with a faster wire speed. Do not try to run a bead, you'll burn right through with the hot flux cored wire. Instead do a stitch weld, moving from one end to the other tacking the metal until you have a uniform weld. It takes time, and patience, but I've done body panels, rust repair, even welded in larger wheel wells in a XJ with flux cored. Practice makes perfect, and get ready to grind down your mess!
 
#20 ·
MIG always has lots of spatter, flux core is the worst. You can get some spatter spray to keep it from sticking, or just use the nozzle spray. That grade five bolt you welded was probably cad plated, anything with a coating like zinc or cad is going to blow up like that.
 
#22 ·
Mig has lots of splatter? Really? As you can see in this pict the burn has not been removed and it is a fresh bead. There has been no spray applied either.
I get this kind of bead pretty regularly with my mig, I do get a buck shot or two every now an again but not often.

 
#23 ·
^^ yeah i dont know what he was talking about mig with lots of spatter... more like

mig with improper settings, weld angle, and or weld speed has lots of spatter.

now i want to play a game... guess the welder. Are you using a millermatic? With 100% Argon?

just thought I would guess :D
 
#34 ·
How far are you holding the tip of the gun from the piece your welding? You want to hear bacon cooking while your welding :drool: mmmmmm bacon.... back on track, If your using MIG outdoors, maybe you should think about getting something to shield you in while your welding, wind will disrupt the gas flow..

If your using a Stick welder or Flux... yea, its going to be splatter city.. deal with it. The grinder is definitely your friend!

Get some metal and practice, I've been welding for 3 years now, Ive done everything from TIG welding aluminum battery boxes on trucks, to flux core welding exhaust manifolds that were leaking. And I'm still learning every time I get behind the trigger :cheers2:

Check the tips page for miller, good info here.
http://www.millerwelds.com/resources/tech_tips/MIG_tips/
 
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