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  1. The thinners it's based on - is there a cheap...

    The thinners it's based on - is there a cheap alternative? E.g. if I run out on a Sunday and need to do cleanup can I just use metho or turps from a hardware chain? Or do I need to find the right...
  2. I like the killrust paint system. But I've had...

    I like the killrust paint system. But I've had similar results with the primer as I did with metalshield - the primer sprays great the first time but if I try to use it again a few months later it's...
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    Keep a scrap file handy and/or clamp a scrap...

    Keep a scrap file handy and/or clamp a scrap strike plate next to the work. Knock the old flux off on the file and/or strike on the scrap and then move to the work while the rod is hot or when...
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    Geminis are dirt cheap but you might have to...

    Geminis are dirt cheap but you might have to search to find them. Last time I bought some boxes they were either $7 or $11, I don't remember. They do 2.0mm and are usually stocked. 6012 and 6013.
    ...
  5. Further to my last post, the lanolin spray you...

    Further to my last post, the lanolin spray you can weld through if you have to. It smells exactly as you'd expect burnt sheep grease to smell and I doubt it's anywhere near as bad as paint or galv....
  6. Don't weld through paint unless you have a strong...

    Don't weld through paint unless you have a strong fan blowing the fumes away. And even then, don't. It stinks and I hate to think what the fumes might do to you. Even an inch away it stinks. It...
  7. Thread: A build thread

    by Legion
    Replies
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    4,591

    I've always wondered - how are you going to bend...

    I've always wondered - how are you going to bend the top beams? I've got a killer pipe/tube bender but it's not going to cut it for big beams like that and I wouldn't mind some curved pergola beams....
  8. Thread: A build thread

    by Legion
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    4,591

    Those will be some thick caps.

    Those will be some thick caps.
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    I had a problem with a control board on my...

    I had a problem with a control board on my dynasty. One phase of the AC cycle wasn't working due. It was repaired under a no-questions-asked warranty. The service guy loved blue but didn't see many...
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    I've got the Kemppi 140. It's exactly the same...

    I've got the Kemppi 140. It's exactly the same machine as the 150 but with a 10A plug and a couple of different stickers. It even comes in a box labeled as the 150. It's a great machine but I've only...
  11. Thread: A build thread

    by Legion
    Replies
    42
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    4,591

    Looking forward to it!

    Looking forward to it!
  12. Thread: A build thread

    by Legion
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    4,591

    Stick process?

    Stick process?
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    My vote is for outside corner. But realistically...

    My vote is for outside corner. But realistically any of those joints should be more than strong enough for a little fabbed tube like that. For neatness' sake if you don't want to try an outside...
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    I was thinking, all this talk of dirty air - I've...

    I was thinking, all this talk of dirty air - I've got clean air but what about the cut material? Does rust make the cut messy? Does it destroy consumables even if the air is clean? How about...
  15. I wear a 3M 7551 mask for painting. Obviously it...

    I wear a 3M 7551 mask for painting. Obviously it would never fit under a welding hood.

    As per the other thread, I tig duragal all the time just flap wheeling the outside. No issues with fumes...
  16. How on earth did you keep that straight?

    How on earth did you keep that straight?
  17. Position the job so you're welding in a 1F...

    Position the job so you're welding in a 1F position, maybe with a slight (20-30°) downhill. 2F or more is harder. Position makes a big difference to how heat travels and the effects gravity has.
  18. Do two or four brackets at once. Do you have a...

    Do two or four brackets at once.

    Do you have a compressor? Blow air on it.

    Do you have a big block of copper or aluminium? Use it as a heat sink.

    If you put it in water, you'll promote flash...
  19. I've learnt purely from youtube and forums. Some...

    I've learnt purely from youtube and forums. Some might say that's obvious, but I have fun and produce half decent results
  20. Since it's painted, yep, the wire brush will...

    Since it's painted, yep, the wire brush will clean it off. Gentle, gentle with the flap disc on thin material. Particularly on corners, they can take away a lot of material quickly. Actually, you can...
  21. They had you working on thick stuff because it's...

    They had you working on thick stuff because it's easier.

    Machine is just so we have an idea of whether the machine is going to make life harder.

    I can (could) do 1.6mm material but it's...
  22. The tube probably won't be 3.0mm. That's a bit...

    The tube probably won't be 3.0mm. That's a bit thick unless it's bigger tube.

    Don't buy 1.6mm rods. They're hard to use. 2.0mm are OK.

    Easier to hear what you're using first, i.e. no point...
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    For my water trap I bought a ~10m copper tube,...

    For my water trap I bought a ~10m copper tube, coiled it up and stuck it in an 11L bucket, one of those white plastic ones the same build as the white 20L but half size. On one end I have a male...
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    I like this advice, Mick. I will try it. I'd...

    I like this advice, Mick. I will try it. I'd really like to consistently do full circumference welds with no visible stops or starts. I can do that on straight runs but not around corners. I'll need...
  25. That's surprising. It would suggest not enough...

    That's surprising. It would suggest not enough current to me. Are these the 4.0mm rods? Anyway, clamp a scrap piece of plate or sheet to the circuit and drag the rod over that so it's hot (or run a...
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    I had a bit of spare time this afternoon so...

    I had a bit of spare time this afternoon so experimented a bit more to dial in the settings on this material.

    2.4mm 2% lanthanated
    2.4mm ER70S-6
    #5 or #6 cup
    ~6L/m argon
    50mm x 50mm x 3.0mm...
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    Thanks Mick. To get the low amp fillets...

    Thanks Mick.

    To get the low amp fillets looking ok I had to weave _a lot_. Same with the low butts. I had to hover in a spot to get it to melt and then little mini dabs with filler. Not how I like...
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    If you are using something like Sketchup you can...

    If you are using something like Sketchup you can get a fairly good idea. My trailer came in within about 50kg of my estimates at the weighbridge and the steel structure would have been within 5kg...
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    Some chain isn't weldable. And certain VSB1...

    Some chain isn't weldable. And certain VSB1 guidelines stipulate non-welded chain iirc.

    If you made cage sides fixed, they could add significant longitudinal stiffness. Three fixed sides (sides...
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    Foot pedal, but I floor it until the end and only...

    Foot pedal, but I floor it until the end and only use it to taper off. I don't feather throughout very often.

    The filler for me depends on the amps. Some guys on US forums recently have been...
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    OK gazza, I decided to try out an experiment...

    OK gazza, I decided to try out an experiment today using your settings and see what happens. Before I start, this is using my machine and me as the welder so all comments reflect on me.

    This is...
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    If it breaks on the open road and the load goes...

    If it breaks on the open road and the load goes tumbling down the freeway, liability.
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    - be careful welding axles. - drop axles aren't...

    - be careful welding axles.
    - drop axles aren't that much more. I think I paid not quite twice a normal axle.
    - chop up and look at your test welds. Bash them with a sledgehammer and see if you can...
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    I'll see what I've got lying around in the offcut...

    I'll see what I've got lying around in the offcut pile with welds that long in that thickness. So your machine is set at about 57A. 70A for the fillets, right? I'll try those settings and try what...
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    Hey gazza, what dimensions are those bits in the...

    Hey gazza, what dimensions are those bits in the pictures? I might have a shot on the weekend with my machine if I can find some suitable scrap. 60A?
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    I'm just an amateur but it looks like you have...

    I'm just an amateur but it looks like you have enough on the butts. Fillets will reveal more, since it's hard not to melt the edges of an open butt against those radius corners. Some of the weld on...
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    No such thing as a tig helmet, gaz. Any of them...

    No such thing as a tig helmet, gaz. Any of them would be equally suitable to all processes.

    I'd still be cleaning more. On the continuous tube, about half the width. The equivalent down the butt...
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    What shade? Mine goes down to 8 or 9 and I can...

    What shade? Mine goes down to 8 or 9 and I can weld right down at 30A and no doubt lower if I ever need to. I use 9 for mostly everything until I get up above about 120A. Even then the 9 can handle...
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    Yeah, those old rods suck. Scotchbrite's not...

    Yeah, those old rods suck. Scotchbrite's not going to do it, I don't think.

    Your comments about the tungstens raise an issue to me - in a big day of welding I might resharpen 20 tungstens. I'm...
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    You can't quite see but in the first photo I...

    You can't quite see but in the first photo I posted, that's a 2.4mm tungsten and it's still shiny silver and not dulled at all. OK, it's well within it's safe range and all but it stays that way...
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    Gazza, you might have been pushing the limits of...

    Gazza, you might have been pushing the limits of the 1.6mm tungsten. I've seen some charts that put their upper limit in that 70A range. As it got blunter, arc penetration increased and pop! a hole....
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    So it's scratch start and no remote? I'd...

    So it's scratch start and no remote? I'd struggle, so used to hi-freq start and pedal.

    Apparently any DC stick welder is a scratch start TIG welder.

    Gazza, you could cut some of those welds,...
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    I don't do anything to the inside. ...

    I don't do anything to the inside.

    Alternatives:

    - try burning, like you're saying, but zinc still takes a lot of heat I reckon
    - use hydrochloric acid
    - do nothing and deal with it

    If it...
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    I would agree looking at that control panel. On...

    I would agree looking at that control panel. On mine I'd be starting at 100A for 2.5mm. And I've been as high as 140A, but moving along pretty fast and on joint configurations with plenty of material...
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    Re levelling big frames, I saw on some forum a...

    Re levelling big frames, I saw on some forum a good idea using clear plastic tube with water in it. I've been meaning to make a manifold so you can have multiple leads. Tape one to each corner or...
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    I don't normally use pulse, that was just for...

    I don't normally use pulse, that was just for fun. Probably if I didn't, I'd be experimenting with 70A up fillets and ~55A on butts for that 1.6mm material. How thick was your material?
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    I'd be cleaning much further out. I stagger my...

    I'd be cleaning much further out.

    I stagger my welds because excess heat has screwed me in the past. Not just blowing holes but bending things. I never fully weld out a part straight up. If I have...
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    I'm using Lanolin, although I'm cleaning it off...

    I'm using Lanolin, although I'm cleaning it off before welding again, with a citrus spray and then acetone.

    https://www.woodworkforums.com/showthread.php?t=188961
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    Gazza, I TIG up galv most weekends. You just have...

    Gazza, I TIG up galv most weekends. You just have to grind it clean, the same as you would any TIG job (i.e. mill scale, paint, rust). I never wear a mask, although I have a good mask for painting. I...
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    The more of a box you can make, the stronger it...

    The more of a box you can make, the stronger it will be, if that's an issue. I.e. top tubes from the head tube to the top of the back of the cargo rack, parallel to the ground.
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