STICK WELDING THIN METAL using 120 volt power Beginner Welding Series. Follow along as I repair some thin metal using 6011 electrodes. I discuss metal prep, things to consider when using extension cords and show you a few gadgets to make welder setup a breeze!
Link to Welder:
Link to Metal Thickness Guage:
SUBSCRIBE to Brandon Lund DIY Builds: https://www.youtube.com/brandonlund
THE TOOLS & GEAR I USE
Any commission earned from the above Amazon affiliate links all goes towards helping to support my channel.
FOLLOW ME (for behind the scenes stuff)!
⇨ Instagram: https://www.instagram.com/lunddiybuilds
⇨ Facebook: https://www.facebook.com/LundDIYBuilds
⇨ Twitter: https://twitter.com/LundDIYBuilds
Online Welding Calculator:
For Business Inquiries: [email protected]
Disclaimer: These videos are intended for entertainment purposes only and as such, you should not attempt to do any of the things you see me doing. Always read and follow the manufacturer’s safety guidelines before handling tools. Seek professional advice and training before using any welding equipment. Never operate any tool without wearing the proper personal protective equipment. Final warning, Do not attempt to do any of the things you see me doing!
That works too Dave. I have done it. With that being said, I would never discourage anyone from doing something to better their situation, I would just point out that NMB wire (which is what most house wire is) is not rated to be used as an extension cord. The jacket surrounding the conductors is much thinner than SJ or SO cord (which is what many flexible cords are made from). However, It will absolutely work, just be careful. If you get a small nick in the wire and your using it outside and the ground is damp, you can see where this is going. I hope im not coming off as a negative person. I just don't want to see you or anyone get hurt. Just be careful. Cheers brother and weld on!
First off, thank you. Second, congratulations on getting into welding! I've been welding for many years and I still learn new stuff. It's a lot of fun! Thanks for watching and I appreciate your support!
+Bob Blob If I remember correctly, when its maxed out on 120v it will trip out a 20 amp breaker, but not immediately. I can weld for around 30 seconds when its maxed out before it trips. My plasma cutter does the same thing when maxed out on 120v
only watched 1.5 minutes. You call that thin metal? that's thick! Thin metal is auto body floor pans and car door frames, chassis subframes on 70s-80s cars etc. That's what I want to see successfully welded with 1.6mm and 2mm electrodes.
+Brandon Lund Thanks for the tips! I look forward to the new vids. So far I have managed to make some useful guards/covers with the 16 mil sheet and even managed to tack this sheet to angle iron without completely nuking it. But I have another repair/project that involves (re)welding a piece of rebar to the edge of a 28 mil sheet, where it broke. If you can do something like that with stick, it might make a good video?
+Mildy Productive thin metal is very difficult to weld with stick as you have figured out. Another good trick is to keep a very steep drag angle and keep your pieces clamped tight when doing lap joints. Any gap will cause it to burn out. If you can get a piece of copper over the joint on the backside, it will act as a heat sink and help with blow through. I'll have some more thin metal videos out soon.
I have googled all over for this, myself. The thinnest metal Google wants to show me being stick welded is 14 gauge or about 75 thousandths. MIG, I find videos doing body panels of 18 gauge or about 48 thousandths.
The sheet metal I have been welding is 16 thousandths! I don't even know what gauge that is. I am a noob, but I have gotten it to work fairly ok. Lap joints and spot welds, only. No butts or continuous bead. And I still get the inevitable blow through on occasion. What works for me is clamp next to where I will spot weld, grind a small slot-shaped crater through the top sheet and slightly grazing into the bottom sheet with a small cutoff disc. Heat up a 1/16" 6013 on a piece of scrap, then bring it to the spot. As soon as it sparks, jam it down until it just about touches the metal, and immediately withdraw. Amperage as low as it will burn, which is about 17A on my machine, DCEN. If you were restoring a car, you would need a lot of Bondo, lol. To repair a tank, it would take forever to connect the beads to make it gas/liquid tight and you would maybe need a plug welding heatsink jig to fix the holes. :) (I haven't figured out how to plug holes in metal this thin, yet.)
The other major problem beside holes is warpage. If the spot doesn't take on the first try, the metal warps and separates and the flux dust gets in there. If you can't hammer it flat against an anvil, I have very little chance to get it to connect on further attempts.
I have other videos with 1 and 2 mm / 20 guage if your interested. Stick really isn't ideal for bodywork, however, it can be done and done sucessfully. I've had good luck using copper as a heat sink to help eliminate warping / blowout.
Awesome. Thanks for responding. I'm having a little problems with Oxy-Acetylene T Joints. I've looked all over youtube for Oxy-Fuel welding T Joints and there's only a couple vids but they're not up close or not in detail or I can't see what the person is doing. So I figured I'd ask a bunch of Youtube welders to see if they could possibly upload a video. :D
Oxy Fuel welding is probably my favorite... it takes a fairly high degree of skill and practice to get a decent looking weld. I got my crash coarse about 35 years ago welding in floor pans. It then progressed into custom body work / chopped tops and lead work. I still have all my gear but I have pretty much replaced it all with tig brazing for the most part.
Mercer Frey every electrode has a recommended amperage rating as a starting point. It’s usually printed on the label. Eventually with experience and time, the beginner welder will remember what rod runs with what amperage.
I have not used that specific machine, but yes you can run 3/32" 6011 with that machine. You will be pretty close to maxed out though. That rod runs around 75 Amps. 6011 rods can be used on ac or dc machines.
6011 is the best rod for any job, is very penetrant, you can tun it colder than it was made for, welds dirty metal, and unprepped metal so 6013 is not a good electrode guys it only has a good finish, 6011 is the best option
I'm trying to weld tin cans with an old dayton welder from the 50's...Ive got it on the lowest possible amperage and using a 6013 rod; 1/16th" on 110vac...I cant seem to get it lit, if i up the amps, it just burns right thru...any suggestions?
dan walker Grab a short piece of old copper water pipe. Flatten the end do it sits more or less in full contact behind what you’re welding on. Hold it there with a gloved hand and it will likely weld for you. The copper will absorb some of the excess heat yet won’t weld itself to the workpiece. This works pretty well in cases like that.
Also try using 6011. Because it’s a Fast Freeze rod and may work better for you. You might also try reversing the polarity if your machine has the capability. You sort of have to screw around with techniques in cases like this till you see what is working best for you sometimes. That’s why you need to practice on similar scrap to get it dialed in first.
Don’t fall for that “get out of the Stone Age get a $1000+ MiG or you’re wasting your time” crap. When I went looking for a welder in the early 90s I was told stick welding rods were likely not even going to be available in 10 years........yea sure! I got one eventually, a 135 Hobart, just for body panels. Today my preference is still the old AC/DC Lincoln Tombstone.
dan walker what if you used a tiny bit of tinfoil or a metal shaving to strike the arc on? Then it would burn back instantly once striked. I’ve heard of ppl using their tig filler rod to start their arc but always wondered about this lol
+Jeffrey Chavey You do not necessarily need lessons to make a repair like this. You could literally watch videos like mine and others and probably do a pretty decent job, however, if your able, a few night classes at your local school would probably help. In my opinion, nothing beats hands on instruction where someone can look over your shoulder and give you pointers on what your doing.
So the correct answer is there is always that risk of electrocution when welding. Then there is what actually happens. I routinely brace the rod (especially on thin rods that bounce around) and I wear just standard leather welding gloves. Been doing it for years.
im just a hobbyist, so all i have is a 200amp stick welder i have been teaching myself with. i think its best to learn welding the hard way anyway, then move on to the easier methods when i go take a proper welding course.
not too thrilled at the idea of stick welding .9mm tubes of 4140 either, due to how likely it is il just blow holes in the stuff. so im just getting the best information i can before trying it. at the moment im trying to figure out if i need 6011 or 7018 rods.
this project is my next self teaching course, so i can move on from making garden decorations out of scrap.
Mr Jay White the best process for a bike frame would be tig, but if you don't have access to tig, you could do it with stick but it will be difficult. I have a video about welding sheet metal that might be helpful. If you have access to a spare bicycle, I would do a bunch of practicing first to get your amperage dialed in.
It is so unfortunate that so many people just starting out welding start with a stick welder and try to weld thin metal. It can be so hard! Despite that I have a little 120v everlast stick welder that I learned on and absolutely love it. Welding can be so addicting.
Right on Lucas! I would encourage anyone first learning to weld to hold off on welding thin material until you get proficient with thicker stuff. I'm very impressed with today's technology with how stable an arc can be on 120 volts. It's quite impressive!
Thanks buddy! As I was telling another commenter, 99% of my experience is on transformer based welders, so these little inverter based units really impress me. Im super impressed how well this unit will light a rod and maintain an arc. I really push it's capabilities in next weeks video when I attempt to weld 16 gauge sheet metal with it!
That turned out well, you are right, thats the sort of job DIY folks have to tackle and it usually ends up a mess and they get discouraged, inverter set are a great help, plus of course youtube channels like yours. MIG fluxcore is also handy for jobs like that, but clean up tends to be more time consuming, plus more spatter usually. Using heavier duty cable is a good tip, I was laying out an extension cable once and my wife said "my, thats a very thick wire" made me check to see if the zipper on my jeans was open:)
Thanks for the compliment Jaques! I'm old school so 99% of my experience is on transformer based welders. Going from a transformer to an inverter like this one is like night and day as far as i'm concerned. The inverters are way easier to start and maintain an arc as far as i'm concerned. Time will tell I guess if electronics will win over a solid state transformer machine. My wife has never commented on me having thick wires :) Take care brother!
For the next collection of Free Silly Birthday Greetings Cards.
FUNNY BIRTHDAY QUOTES, SAYINGS & JOKES ABOUT GETTING OLDER.
(Handy quotes to add to your e-cards, text messages, facebook & myspace pages )
Birthdays are good for you. Statistics show that the people who have the most live the longest. Funny Birthday Quote by - Larry Lorenzoni A reporter was interviewing a 104 year-old woman: "And what do you think is the best thing about being 104?" the reporter asked. She simply replied, "No peer pressure." Joke by Unknown Author Im getting older I hear you cry Well. whats the big deal For so I am So make the most of what youve got Cause after all You still look Hot Funny ageing poem by.
Helen Finnerty (copyright 28th October 2011)
The secret of staying young is to live honestly, eat slowly, and lie about your age. Amusing Birthday Quote by.
Lucille Ball Another birthday And some more grey Im getting old I hear you say But never mind For when alls said and done The alternative is Not being around To see another one! Funny ageing poem by.
Helen Finnerty (copyright 28th October 2011)
Billie Burke My wife hasnt had a birthday in 4 years. She was born in the year of. Lord-only-knows! Funny birthday quote by Unknown Author The best birthdays of all are those that havent arrived yet.
Robert Orben I have everything now I had twenty years ago. except now its all lower. Funny ageing Quote by.