Is it possible to......

[evad1980]

....... Butt weld two pieces of 1mm metal together with a 3mm gap between them?

Basically need to join the pieces but at some points there is a gap up to 3mm, I can't cut any off to make it straight as I need all the metal that's there. It took me ages to fabricate this particular piece so making another one I'm trying to avoid if I can!

On first thoughts I'm thinking no....

Any ideas?

Cheers...

 

[chunkolini]

It can be done but is very difficult especially if you are a newcomer to this game.
A naughty bodge I have used to fill gaps is to put thin bits of steel welding rod along the gaps, tack them in several places and then pulse the trigger on the torch as you work along and around the join.
This can be ground back to leave no trace but is definitely a bodge.
I have also manually added extra filler wire almost as though Tig welding again a bodge but it can be done.

Make lots of tacks bridging the gaps, start at the ends of the gaps and work inwards, welding onto the tacks rather then the extreme edge, this builds up a lip that you can work from.

Have a play about with some bits of scrap before wrecking the piece in question.
it can also help to use a backing plate of copper or aluminium, this wont fuse to the workpiece and will conduct heat away and support the edges.

Have fun and dont despair.

 

[Paul.]

Use a backing bar preferably from copper but aluminium will do at a pinch, clamp it tight to the back of the joint, you will fill it no problem, be aware though that bigger gaps will increase the distortion, so keep the heat down by skip welding, and using the thin metal technique, you may need to planish the joint between runs too,

 

[Exuptoy]

I was going to suggest copper too. Just get hold of a piece of 15mm copper pipe and flatten it with a hammer. I'm a bit rough n ready myself.

 

[Jim_gsxr1000]

I have lengths of 2"by 1/2" copper bar for backing welds

 

[Exuptoy]

I have lengths of 2"by 1/2" copper bar for backing welds

Don't wanna sell a piece do you. I'm a sparky but getting stuff off the rigs is dodgy. If I get caught it's my job.

 

[steveo3002]

often cheap offcuts on ebay ..or autojumbles if you ever go

i use a couple of lumps of brass

 

[evad1980]

Cheers guys.. Good info there...