Total Newbie - Am I Mad?

[neelpeel]

I have a project that I am keen to take on...
I have a garden concrete block wall that is about 15m in length and another stair section that is about 10m in length.
I want to knock the wall down (halfway ther already), leaving 2 layers of blocks and then install metal railings instead.
I have never welded in my life, but I'd like to do the whole thing myself. I have a lot of patience and can usually turn my hand to things.

I have a few 'starter for ten' questions.
- What would be the best type of welding to embark on for a complete novice for welding railings and what be a good starter welder?

- Where are the best sources for materials?
I found this website that looked promising... www.forestmetals.co.uk

- Will I really need to go on a course or is it feasible to learn myself and get some decent results?

I'm starting to design the railings on CAD so I'll post some pics once I'm done.

This could be a long project!

 

[Dangle_kt]

QUOTE

"This could be a long project! "

I'd say about 25 metres

You'll need a pretty powerful MIG to do railings of any thickness, be a bugger to struggle to use an underpowered mig for all that! Powerful MIG's are pretty costly, do you have one already?

 

[runnach]

How thick is the concrete block 4 or 6"? Are you proposing to drill top of block and lead in the verts or manu brackets to secure? I would be looking at a sound and safe way to secure new rail, as there are a few variables to take into consideration before getting into the design stage.

Sorry, I do not mean to burst your bubble, but best to get the fundamentals in the correct order. there are also other forum members who are more knowledgeable on the manu and erection of gate/railings who can correct me with the above?

Cheers............

 

[neelpeel]

I think they're 6" blocks.
My plan so far is to drill holes down through the two remaining blocks and secure the main rods in with epoxy or the like. I'm just about to buy an SDS drill and some long drill bits for this purpose.
I've not decided yet whether to weld the railings together piece by piece in situ like this or to try and weld together in sections and then fit as complete assemblies.

Dangle_kt, no I don't yet have any welding equipment whatsoever. I've not even decided yet which way to go...I'm open to advice.

 

[lexi]

If you are welding outside .....get an Arc machine.

Alex

 

[Drav]

If its a long section that needs railing, Id weld in sections. Do all the welding and then erect and join. Unless you're Superman. You shouldnt need to go on a course, you can learn the fundamentals by reading a lot.

Also if you dont have an inside workspace, lexi is right. Get an Arc welder. If you do have a workshop, you could look at 150+ amp migs, but they tend to be more expensive and you cant use them outside except on a day with no wind at all. However, they are easier to learn with.

 

[Davek0974]

Watch out when you reach the design stage, AFIK there is a building reg that states you should not be able to get a 100mm ball through the gaps between railings etc.

Its a safety thing.

dave

 

[neelpeel]

Yeah, I read about the 100mm gap thing in another thread. Also learnt that the horizontal railing needs to extend past first step of the stairway (by 300mm if memory serves).
Some invaluable tips!

So...an Arc welder certainly sounds like a good cheap way to get started. Longer term any welding that I do will most likely be outside.
Any ideas of the ampage of unit that I'll need?

I guess it'll be mostly welding 12mm dia (or sq) rods to say 8mm thick handrail material.

 

[neelpeel]

So, I think its time for me to buy some equipment and start practising.
First of all...which Arc welder to go for?
Will maybe look for 2nd hand from Ebay, but which brand and what is a good current range for what I'm doing?

Will also look at buying an autodarkening helmet and decent welding gloves. What other bits and pieces should I get before starting out?

And what would be the best size and brand of rods for welding mild steel railings?

Ah, so many questions...and so many more to come!

 

[MINGER]

I have an SIP 120 amp, its about 30 years old, it looks a rusty old mess, but it still welds perfect. I have had to get new rod pliers, and earth clamp + cables, but the set itself is original, and never needed a repair.

I don't know if SIP still make them to the same standard, but if they do, then SIP cant be faulted.

You will need a chipping hammer or use an old chisel like i do, and goggles, hot slag in the eyes is very painful, and eyes or very valuable things of course, a React to light head mask is spot on.

The size of the rods depends on the thickness of the mettle your going to use really, but generally i would think about 3.25 or 4 mm ish, any make of mild steel rods will do, but the ones i use are ESAB, i bought in bulk many years ago, these rods are quite old now, i don't even know if ESAB are still around anymore. Murex which were made by British Oxygen i think, were a good rod, when i used them many years ago.

Your best bet is to go round the local car boot markets its amazing what you can get there and cheap too.

 

[heinz57]

Arc Welder

I saw an Arc welder on Ebay by the brand name of Tonco, its portable and only £100, oil cooled AC so will probably last forever, ive been tempted myself
but the duty cycle is only 20% at 140 amps, that might be enough for you, worth checking out anyway!!! let us know how you get on.

 

[Faaluke]

Don't forget to check out Weldequip's shop on this forum.

http://www.weldequip.com/mma-welders.htm

If I could give any advice, it would be to not buy a rubbish welder. No one ever complains after buying a good welder

 

[heinz57]

Hi Faaluke, whats the work situation like in New Zealand, much welding about mate?
I was tempted to come out there as im a Plumber by trade.