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  1. #11
    The Shark AR13's Avatar
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    11-18-2015
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    Another question I just thought of - will practicing without gas increase the learning curve? I've heard through the grapevine that "gas makes it easier to run a bead" and things of that nature.
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  2. #12
    Freaking JK Guru TheDirtman's Avatar
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    As long as you have the heat and the speed right flux works fine. It works better in windy conditions too if you are outside.

  3. #13
    The Shark AR13's Avatar
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    Good deal. I used to work for a mechanic and he had a nice welder, I could attach a couple of exhaust pipes occasionally with no leakage (it wasn't super pretty) but I remember when we got this thing it would just pop and leave crap everywhere so I'm guessing it wasn't adjusted correctly like the one I used in the shop.
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  4. #14
    MallCrawler huufhearted's Avatar
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    It may have already been mentioned, but not only are the settings critical (voltage applied, line speed), but speed of the gun also is a big factor. Ideally you want your hand speed to compliment your wire speed and "heat" from the welder. A good bead will be very consistent in sound and size with good penetration. If your wire speed is too fast, it will be a thin bead with a lot of popping and slag as you are adding more material than can be actually welded to the part. Going too fast with the gun will do much the same, you will get a small bead, no penetration, and will look ugly. If the wire speed is too slow, it will take a while to get the right size bead, introduce more heat than necessary, which will cause burn through and warping. Flux core is bad about this. My experience is that with MIG, it doesn't heat the metal as fast, and it's easier to lay a consistent bead with a wider range of settings. But if you can master flux core, moving to MIG is absolute cake.

    Also look at getting an anti-spatter gel for the gun tip. Especially with Fluxcore. This will keep the gun clean longer, and keep the slag down as well. Get a good wire brush as you will want to clean the tip of the gun frequently and it can be used to clean the weld after fluxcore. It produces a film over the bead, and if you have to weld another bead next to it, or do touch ups, it has to be cleaned. The gun tip should have a nice copper color. I usually clean the tip of the gun after a few welds. It doesn't take very long and will help with the electrodes ability to create the weld. After welding for sometime, you will notice that the beads will take longer to make, or you get more inconsistent popping, most likely due to a dirty gun tip.

    I took a welding course a few years back and the first few days were taking a scrap piece and making a bead. I wasn't attaching anything, just drawing with the welder. This will help with settings and work on hand speed. You could lay about 10-15 proper beads on a piece of metal about 3"x4". Set your welder to the recommended settings, most brands have these, then practice making straight passes at different hand speeds. The internet will have good examples of what your bead should look like in thickness and shape.

    One of the key statements I remember from the instructor is to weld comfortably as possible. This isn't always possible, but when starting out, get as comfortable as you can. Try making a bead going different directions (again on a flat piece) and with either hand. You may find that your non-dominant hand makes a better bead. For me with TIG (it takes two hands), I make a better bead when I use my non-dominant hand in the conventional spot most people use their dominant for. Switching hands will also help when you have to do complicated welds, especially with tubing or tight spots.

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  5. #15
    New JK Freak
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    Quote Originally Posted by AR13 View Post
    Good deal. I used to work for a mechanic and he had a nice welder, I could attach a couple of exhaust pipes occasionally with no leakage (it wasn't super pretty) but I remember when we got this thing it would just pop and leave crap everywhere so I'm guessing it wasn't adjusted correctly like the one I used in the shop.
    The popping sound and the splatter you are referring to is called "short arc". welders use this method on thin material or in vertical welds. it keeps the bead from burning through or falling off the metal while welding vertical.

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