Since welding seems to be so much a part of building a rig (and 'cause I need some help), how about putting a section in the Tech Dept that deals with techniques, heat control, tips, pics of good and bad welds, how to adjust amperage and wire speed, and other things I'm not even thinking about?

It is hard to describe technique without showing a person. It might be better to get e book on how to weld. Got any questions in particular?

Well, I guess for starters, my welder has four heat settings. How do you pick which setting to use? What's a good rule of thumb for setting wire speed? I can also use .023 or .030 wire. I've found that it's easier to weld vertically using the .030. I've also heard that .023 will give you a hotter weld. What wire is better to use in particualr situations? Does the fact that .030 is easier to weld vertically mean that my weld is colder and not getting as good penetration? I've heard of people using a "Z" pattern or a circular pattern. I just try and keep the puddle in the middle of the two pieces of metal, with varying degrees of success. Should I be zig-zagging in a particualr pattern, and is there some special technique I should use. I'm getting a lot of booger welds and I'd like them to look better AND hold. Some one used the term "slug" in a previous post as in I would get one in a weld and it would crack. What is a slug?

Well it sounds like first off you need the basics. What i would do is get a 101 welding book or text book. It will answer alot. Do you know any welders? A good idea is to get your helmet and watch.

I would go with the .030 wire and stay with it. Dont keep changing stuff until you learn the difference. Learn to weld with one wire size.

It sounds like mig. Are you using gas or flux. What mixture of gas are you using? You have 4 heat settings you say? You should also have a speed setting that will speed up or slow down the wire. Now grab some 1/4 inch scrap plate. Crank up the heat onto the highest setting. Start the speed setting at around 1/3 the way. Start welding a bead and adjust you speed setting while welding (or have someone do it) until you get a popcorn sound. You may have to speed up the wire or slow it down but it will get to a point where is sounds good. You have to listen to it as well as look at the weld.

Just practice laying beads on flat steel. Now using mig you can go backwards or forwards. Thge best way usually is going fowards in a zig zag or like a 'c'. Depending on the welder sometimes you dont even have to zig zag. These are usually big welders which you dont have.

The main thing is to practice on scrap stuff until you get good enough to fab something up.

It's a 230V/120A mig welder. I'm using 75%Argon/25%CO2. I have welded up some stuff on my trailer, an anti wrap bar on my axle, shock mounts, brackets for my Hi-Lift on the tire carrier. I would just like to get to the point where I can weld suspension stuff, which I don't trust my welds for yet. I am planning on taking some classes when I can make the time, but I'm putting in mega hours at work right now and finishing the remodel on my house, so classes to help my hobby aren't an option right now. What about picking the right heat setting, heat control, etc? How do these guys these perfect looking welds I see on everyone else's Jeeps?:confused:

Originally posted by withamc
It's a 230V/120A mig welder. I'm using 75%Argon/25%CO2. I have welded up some stuff on my trailer, an anti wrap bar on my axle, shock mounts, brackets for my Hi-Lift on the tire carrier. I would just like to get to the point where I can weld suspension stuff, which I don't trust my welds for yet. I am planning on taking some classes when I can make the time, but I'm putting in mega hours at work right now and finishing the remodel on my house, so classes to help my hobby aren't an option right now. What about picking the right heat setting, heat control, etc? How do these guys these perfect looking welds I see on everyone else's Jeeps?:confused: I have a little Lincoln 135 mig and under the cover is a chart on wire speed and heat setting for different thickness metal. It's not exact but it's pretty close. If yours doesn't have that look in the manual on yours. I use a circular pattern when welding thick stuff 1/4" at the highest setting. I am by far not a great welder, I too need alot more practice. Build a rack or something that reguires alot of welds and you will get good in no time. :D Just practice and you will get it.

Does your regulator have 2 guages? If it does then set the flow to 15 CFM. As noted a few posts up weld with the gun behind the direction of the weld (push the weld puddle). The reason to do this is because the gas flow needs to be out in front and leading the weld not be after the weld. Most of the time this isn't a big deal but it does make for a better weld and a better looking weld because if you pull the weld it most often leaves a humped up weld like the wire speed is two slow. The only time I pull the weld is on a vertical weld. I have a much easyer time keeping the puddle up and getting a better weld that way. Like the other guy said set the welder to the hottest setting and stratr playing with the wirspeed. If your welder has a 1-10 wire speed range I bet it will weld best at 7 or so but you will hear it when it is right. If the speed is too fast you will feel the wire hitting and pushing the gun back and if it is too slow the wire won't make it to the puddle before it melts. These are the 2 extreams so this will get you sort of close to the right speed. When the speed is right it will have a nice steady crackly hiss. With a 120amp welder you are realy limited to what you can realy weld. Don't even try welding something you rely on, on to the axle housing with it. The limit is weld things to the frame and be sure to clean the surface of what and where you are welding. So with this welder I wouldn't drop below the top 2 settings other than thin box tubing and when welding thin metal use the trigger on and off and this will realy help you to not burn through. Have fun