Wire Welding
Voltage = arc length (you can think of it as weld width)
IPM = filler material (weld depth) + penetration
If your using flux core wire then remember to keep stickout (distance between electrode tip and steel) longer than you would with gas shielded wire. 1/2" should do...
Go gas !
a 75/25 mix works good for what your doing we use .023 and 75/25 for repairing body work almost daily. If you are outside and have a breeze you will need to set up a windblock.
good luck
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Ouch
You are SO correct I teach secondary and post secondary welding and I am constantly preaching about safety glasses and just yesterday I was troubleshooting a mig welder problem, lifted my glasses to see something better and poked myseld in the eye with .035 wire !
Speaking of old cars...
Malcom had some good points
Aluminum wire with mig is a touchy subject if you can't pulse. However, before we went to pulse we did it daily.
-Clean ! and wire brush or use a disk pad to remove oxide layer
- I must admit Ed Craigs weldreality site has more specific paramenters on what you are...
It a great question
We constantly get people in our classes who purchase a small wire welder and take it home then complain about the quality of welds. So, I purchased 3 of them and they sit side by side.
1- has .030 flux cored wire
2- has .030 70 s-6 wire and 75/25 mix
3- has .030 70 s-6...