newb questions not googleable

[robertbruce]

tried to google these, could't drill down to what i needed...

1. How often do I dip my tip into welding stuff?... I keep getting fire or waxy depoist....

2. For thin patch-panel steel, is it ok to turn my gas regulator right down to just above TIG levels?.... At the reccommended level I swear the gas is blowing the pool through the steel

3. Can anyone make any comment about the burn stains on these patch's, i get them on the welded side too...

4. I can't seem to patch with the reccommended gap/wire, ie .6 wire=.6 gap. When I use .3 gap is fine. Is this normal?

what a difference 0.3 of a gap makes.... i like my penetrations here

5. Preparation is king, i understand that. What is the best tool to clean up the edges of patching panel?...

6. Do expensive snipers like Weiss, make a non-deformed clean cut?... my current snippers leave bend the steel and leave a serrated edge that acts like tinder helping to blow out the edges...

7. Is there such a thing as a "Silent Grinding Disc"?, i feel my my neibours hate me...

Thanks for any feedback...

 

[pedrobedro]

Tip dip is optional, I've never used any, spatter doesn't stick to copper shrouds much.
Indoors you can turn the gas as low as will do the job. Tig levels ? 5 or 6lpm works for me and you can hardly tell the gas is flowing.
You get burn stains because you are heating metal to melting point, it's very hot don't touch it.
On thin material up to 2 or 3 mm you don't need a gap if your welder is powerful enough, less is better. Who recommends a .6 gap with .6 wire ?
Clean up is down to preference, I use fibre discs some use cup brush or flap discs.
Bypass snips have to bend one edge to cut, nibblers cut a wider line but leave it flat.
Your neighbours will always hate you, it's their problem not yours.

 

[keith19]

1. If you are using proper dip, and not vaseline, about once or twice a shift on thin metal.
2. Turn it down to about 7 litres a minute and see how you get on. Going lower with mig is not generally advised.
3. The heat affected zone 'burn stains' are quite normal, they show up more on some metals than others.
4. The gap is generally based on the metal, not so much the wire. You don't need any gap on thin metal up to about 1.2 or 1.6mm, it just makes the job more difficult; you are liable to get more blow through.
5. Flap disc on the top and bottom. File along the edges if you don't have lots to do.
6. Expensive snips are better, but cheap snips and a file are still cheap and good. All snips bend the steel, a bench cutter is better if you can justify it. Still bends big sheets though.
7. No, haven't found one yet. I generally wait until they are out for the day....

 

[Sean]

7. flap wheels are quieter once they have broken in -just, but main thing is they are much more forgiving on the surrounding metal.

 

[rich r]

Air tools can be quieter, but you'll need to site the noisy compressor somewhere the neighbours can't hear either. However, unless you've got a big compressor, air grinders aren't as powerful as electric ones.

 

[Wedg1e]

A lot of the noise from a grinder seems to be from the bevel drive...

 

[robertbruce]

many thanks for the comments... especially regarding the gap, grinders and dip.... might try to get a electric nibbler

 

[chunkolini]

Cutting sheet metal quietly on a budget these are great http://www.machinemart.co.uk/shop/product/details/cps75-mini-sheet-metal-cutter.
Impressed by your approach to learning a new skill and record keeping etc.

 

[robertbruce]

ta for that Chunkol, I enjoy learning new things and i lurveee my engy' chalk...

many thanks to this forum and the excellent flash-clips...