Right chaps what are my chances of puddle welding a 0.8 mm sheet to a box profile frame , I only have an inverter stick welder and 2.5 mm rods , it's to form the skin of my landy tailgate , is it possible ? Given mediocre skills ,
Cheers
Focus the heat on the thickest part of what your welding that's probably going to be the box section. You can buy 1.6 welding rods and turn the welder down low . I often got them in Halfords for welding excaust pipe
pop rivets are your friend , then you could use alloy , and it would match the rest of the vehicle , may look tidier, if you have rivets , if not , when your out shopping for them , buy smaller rods then you have the weld option too .
Otherwise given what you have to hand its a very tough job and be even harder to get it to look tidy.
I agree with @tom2207, if it's not structural then pop rivets evenly spaced would look good. With 2.5 rods, you may get away with working at the kind of amperage you'd use for vertical-up on thinner material and by directing the heat to the box section, but be prepared for the rod to stick and splutter now and then. If you have any odd bits of similar materials, then I'd be inclined to do a bit of practice before committing myself.
Ok fellas rivets it is , screwfix here I come ,lent my pop riveter out ,never saw it again ,grrrrr , sold my mig welders years ago , to another forum member
Cheers