welding thin gauge steel.

[bigdreamin]

Tomorrow I am going to do some welding on my truck tomorrow to fix the torn out door striker. I think it's 20ga steel, anyone who has a gen 2 Dodge knows what I'm talking about. Anyway any tips on super thin steel? I'll be using a Hobart 135 with .035" flux core.

[PaulT]

It would be easier with thinner wire. I use .023 but thats with a bottle. I dont know if flux core is made that small.

[DSW]

On and off the gun, weld in short lengths and give it time to cool. I don't know about the flux core wire, do'nt use it myself much at all. If you can access the back side of the weld a heatsink material would probably help. I often back up thin weld with a small piece of copper to help preven burn thru.

[47jheep]

I've used the flex core and I gotta agree using the bottle is better... But you can do this, dial the setting down to your lowest setting, slow feed on the wire and use a tacking type approach. Tack in one spot then tack in another spot an inch or better away, keep doing that until you've finished. Take you time, let it cool for awhile during the process.

[norcalkid]

if your gonna use the flux core wire get 0.30 wire and run it on a low setting. .035 seems kinda big for sheet metal, it burns thru alot easier i noticed.

[odin544]

try and find some thin stuff to practice on. .035 flux core is definitely not ideal. I have that in one machine here and .023 solid core on another. .035 looked crappy and burned through easy. .023 looked great when I was done replacing the rockers. good luck.

[bigdreamin]

I would use shielding gas and solid wire but I have neither. nor a place to put them until my garage is finished. :( For now I have to make due with what I have.