Keeps blowing through...help!

[biosbill]

Hello,

Welding a discovery with my clarke 130en, gasless with 0.8mm wire. Big problems!

I cut out as much rot as I thought I needed too, back to good steel anyway. made up a let in plate out of 1mm. Used a welding magnet to hold the plate in place, and away I went. Both faces were clean and earth clamp was good.

I just keep blowing through and it feels like the welder is set way to high....im on the lowest power setting (1 min) and its still blowing through. I did have the wire feed set reasonably slow, but turned it up to about 4 maybe 4.5 and it seemed better.

What can I do? Weld faster? 0.6mm Wire? Faster wire speed?

Im currently in the middle of one side but have tons more to do so any help will be greatly appreciated!

William

 

[W4yne]

Very difficult to weld such thin metal using gasless "virtually impossible" 0.6 wire would be a better preference but I don't believe it's available for gasless?

For welding such thin metals you really need to be looking at Argon/Co2 gas and a good quality 0.6 wire.

Hello,

Welding a discovery with my clarke 130en, gasless with 0.8mm wire. Big problems!

I cut out as much rot as I thought I needed too, back to good steel anyway. made up a let in plate out of 1mm. Used a welding magnet to hold the plate in place, and away I went. Both faces were clean and earth clamp was good.

I just keep blowing through and it feels like the welder is set way to high....im on the lowest power setting (1 min) and its still blowing through. I did have the wire feed set reasonably slow, but turned it up to about 4 maybe 4.5 and it seemed better.

What can I do? Weld faster? 0.6mm Wire? Faster wire speed?

Im currently in the middle of one side but have tons more to do so any help will be greatly appreciated!

William

 

[biosbill]

Damn, how'd I guess you'd say that!

I dont think you can get 0.6mm wire for gasless either, I certainly havent been able to find any!

I think ill have to sort out getting some gas and 0.6mm wire. How long do the disposable bottles last? Is it really like 10mins, because they're like £7 arent they?!

Thanks so much,

William

 

[bigbadbugga]

Have you tried the pulse/spot welding technique?

Just do a series of quick spot welds close together

 

[lewis s]

I have a 130EN and have been doing some body repairs on a Morris Minor. with 1.0mm steel and gasless wire i have managed to be ok, but seem to be welding quite fast. But it can be done. Gas wire seems a lot easier though, but i am welding outside and as soon as the wind blows slightly it splatters loads

 

[biosbill]

Have you tried the pulse/spot welding technique?

Just do a series of quick spot welds close together

Funny you should say that! Cheers for the suggestion .

I have a 130EN and have been doing some body repairs on a Morris Minor. with 1.0mm steel and gasless wire i have managed to be ok, but seem to be welding quite fast. But it can be done. Gas wire seems a lot easier though, but i am welding outside and as soon as the wind blows slightly it splatters loads

Thats a re-assuring at least.

Anyway, I ran out of wire in the end but I started to get on much better. I suspect I just hadnt cut out enough metal and it was still to thinned by the rust. I did a few more patches after writing that post, with the wire speed about 4 or 5 and doing loads of little spot welds occasionally (if the material looked to be able to take it) did a few in succession....was just gauging the heat in the steel so as not to blow through.

Im going to get some more wire and think I should be ok for the rest of it, was just doing about the thinnest bit on the whole car, I suspect it could've been 0.8mm, plus some thinning due to rust!

Thanks so much!

William

 

[weldmeister]

good call its getting to hot do an inch here an inch there

 

[biosbill]

Thanks again for your ongoing help.

I think ive got the hang of it now, but previously I think I was trying to weld to something far too thin. I tried again welding with 1mm and it didnt seem too bad, could even get a good weld bead going without needing to spot weld .

William

 

[breezer]

Another vote for stitch welding from me

Spot wait a second spot wait a second etc.

Been doing that one some 1.5mm steel, and even on some 3mm steel with good results. You get quite a neat finish as well as you have more control over it

 

[biosbill]

Cheers again all...to tie up this thread a few pictures, ive cracked it .

I usually start the arc on the thickest peice of steel, then get a nice hot weld pool and dip across to the other peice, thus ensuring a strong and neat joint. If you time the length you heat the spot for you can get the weld to sit practically flush and penetration on the other side too. If you try and do two at once when the sheets are too thin: you just blow through. For thin stuff stitch welding has to be the way forward!

Oh and this's all with a Clarke 130EN, setup GASLESS! Im quite impressed even though I say so myself .

William

P.S A quick shot of my Arc welding too...am I a complete novice?!

 

[Dusty]

Youre getting quite clever at this now, bill. I too have a rusty disco but the rear arches arnt quite so bad, the rear floor thou took a lot of work.....
good idea that puller enjoy, Dusty

 

[biosbill]

Cheers .

Yh I got this one really cheap and it was in the village I live it...I didnt really like the colour to start but im getting to like it more now....

Ive got to sort out the rear crossmember, fix the bodged in rear floor then do a little more welding on the sill on the other side. Then the inner wings need a little attention...its all slow work really but it'll be good to have a rust free disco (for a bit, until it starts going again!)

Thanks,

William

 

[bluebobtail]

Hi there, i to am welding up a discovery, the wheel arches aren't as bad as yours but the sills, inner wings, rear crossmember and floor have all gone through.
I looked at making some panels but i went to yrm metal solutions
http://www.yrm-metal-solutions.co.uk/discovery-parts-9-c.asp
Above is all there disco panels. they fit really well.
The floor is quite bad so just opted to buy a new floor. save time and money in the long run.
I just have to drill out all the spot welds for it now.
Keep up the good work

 

[biosbill]

Cheers....ive reccomened a few people to YRM over on my usuall haunt...www.landrovernet.com (same username) But I really dont have a budget to do this car at all, so im making everything and its teaching me yet more !

William