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Old March 8th, 2006, 08:30 AM   #1
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Default Welding advice needed

Project: Redoing bracketry on my front D44. All brackets will be 1/4" wall and axle tubing is 1/2" wall.

Welders:
220V Lincoln Mig: 175A, .035 wire, 90/10 gas mix
220V Lincoln Arc: 225A max output

The plan is to use the MIG to build the brackets. Its a little under powered for 1/4" but I've done other projects with it and its worked well. I want to use the Arc to weld the brackets to the tubes but I'm not sure what size rod, type of rod, and what amp setting I should be running for 1/4" to 1/2". I've only run stick a few times so I'm planning on plenty of practice first.
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Old March 8th, 2006, 08:54 AM   #2
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Since you are welding to the tubes, you shouldn't need anything special in terms of rods. Welding to a cast pig would be different..


Why not just use the MIG for everything, though? My 175A lincoln has plenty of power for 1/4 mild steel.

My suggestion, would be to swap in a 0.045" liner and run 0.045" flux core(remember to reverse polarity).. a 1-2 lb spool of Lincoln Innershield wire should work fine, and its plenty of power for 1/4" bracketry.

Either way, flux core or stick, they are basically the same.

Save the MIG for sheet metal. Flux Core is superior for cleaning, penetration, and work on dirty or rusty metal, outdoor work, and thick metal, since flux protects better and longer than shield gas.
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Old March 8th, 2006, 08:56 AM   #3
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BTW, for 1/4" I still use 0.035" flux core, but for above that, 0.045" is recommended.

On the D heat setting on my 175 (Heat settings A to E), and a wirespeed around 2 (from 1-10), I have no problem at all with 1/4" steel.
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Old March 8th, 2006, 09:12 AM   #4
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I'd use the MIG for all i'm just not sure its going to get enough penetration into the 1/2" wall tubing. i really dont want to run flux and i dont want to spend the money to run .045 mig wire in my machine. thats why i was going to use the stick.
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Old March 8th, 2006, 09:27 AM   #5
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A 0.045" liner is like $10, and another $10 for wire. Or spend the $20 in rods. Either way, you are spending little cash.

Most likely, You will get a better weld with the MIG than with a stick that you aren't practiced with.

That wire feed machine has more than enough power to weld on bracketry on to that axle.




Yeesh, you have 1/2" thick tubes on an XJ...
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Old March 8th, 2006, 09:32 AM   #6
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When I welded my bracketry on my 8.8 I used 7018 and did triple pass. I forget what power I used....turned it up enough so that the stick didn't stick I wan't to say around 120 or so. I ran that for 2 years on 35's and swamp jeep is still running it. I used a Lincoln 225 AC stick welder
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Old March 8th, 2006, 09:37 AM   #7
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Your looking to deep into this... Your 175 will do great. Bevel the edges of all your bracketry and you will penetrate just fine.

A lot of people acomplish this with a 110 welder. (though not recommended)
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Old March 8th, 2006, 09:40 AM   #8
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Quote:
Originally Posted by Haggar
A 0.045" liner is like $10, and another $10 for wire. Or spend the $20 in rods. Either way, you are spending little cash.

Most likely, You will get a better weld with the MIG than with a stick that you aren't practiced with.

That wire feed machine has more than enough power to weld on bracketry on to that axle.




Yeesh, you have 1/2" thick tubes on an XJ...
maybe i'll run to the welding store and see if they've got the liner.

yeah my front 44 has 1/2" thick tubes
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Old March 8th, 2006, 05:16 PM   #9
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Yo chris trailer that bitch towards my house i can weld it at my work. I got a job at a large corporation, We fab stuff for chrysler, ford, chevy, bmw and a few others. I think i owe ya a favor still don't I? PM me back
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Old March 8th, 2006, 05:19 PM   #10
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just do it :tonka:
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Old March 8th, 2006, 05:25 PM   #11
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Quote:
Originally Posted by wakebabe
just do it :tonka:
yeah i know
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Old March 8th, 2006, 10:35 PM   #12
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I will say, I've had trouble finidng a .045 liner in stock, but they can be ordered in a few days..

I'd have no worries using my weld pak 175 to do that with 0.035".. I just built my whole truck that way...
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Old March 9th, 2006, 01:56 AM   #13
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Just JB weld and Duct tape everything.. then seal it with chewing gum... OK ?
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Old March 9th, 2006, 05:45 AM   #14
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Make sure it Wrigley's.....that other crap doesn't hold up to off road abuse :tonka:
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Old March 9th, 2006, 09:09 AM   #15
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Quote:
Originally Posted by Haggar
I will say, I've had trouble finidng a .045 liner in stock, but they can be ordered in a few days..

I'd have no worries using my weld pak 175 to do that with 0.035".. I just built my whole truck that way...
yeah i talked with the guy at the welding store and he didnt recommend using the .045 in my machine. i'll just use the .035 or stick it.
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Old March 9th, 2006, 09:52 AM   #16
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If you are worried just Pre-heat the tube w/ oxy-accty. then run a bead. Definately run the .035 wire you would need some more power for the other stuff and it is more of a pain to get it all set up and get used to that wire. Just call me up when u are going to do this and i can come out there and give you a helpful hand.
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Old March 9th, 2006, 10:25 AM   #17
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Should be fine with the 0.035"

0.035" flux core will get better penetration than 0.035" in GMAW process.

You also mentioned you are using 90/10.. assuming thats 90% argon, then that might also be contributing. More CO2 = more penetration. Running pure CO2 would help, if you want to stay MIG..
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Old March 9th, 2006, 01:32 PM   #18
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Everyone is overthinking this.

There is no reason to change to flux, change your gas, stick weld it....

Prep your metal right, use the right techniques and you will be just fine with your current setup.
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Old March 9th, 2006, 05:10 PM   #19
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How clean is the metal... if its clean use a 7018 rod whatever thickness you prefer. If its dirty use 6011, just make sure you have a slag hammer. Just do not use 7014, 7014 is a flat welding clean metal rod. Depending on the thickness of the metal you might have to turn it up a little but Id say 120 is overkill. You should be fine arround 110. If you use 7018 burn the sucker in, make a couple of passes. good luck

But as Monkey said.. whatever you are the most comfortable with use, your mig should be just fine if you use gas. I would suggest 25/75 Co2/arg


Good luck man

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Old March 10th, 2006, 12:18 PM   #20
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i'm just going to use .035 mig.
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