i want to learn to weld...

[rbattelle]

Greg, what are we looking at in those pictures?

Ryan

 

[Steve St.Laurent]

Do you like foot or hand control?



John

I only have a foot control so I couldn't tell you. I have a feeling that I would prefer the foot control but there have been times that a hand control would have been very handy to have.

 

[GHarman]

Ryan, The brackets are machined from A-36 steel by my brother-in-law on a CNC Mill. The square plates have a 110* arc machined into them to provide a range of motion adjustment of speakers from straight forward to straight down ( Infinite X-Y coordinates completed in a few minures ) Those plates are assembled onto the boss on 2 of the 4 brackets, one left, one right. The plate is a slip fit and has a 1/8" standoff from the face of the boss. The weld is a GTAW 1/8" fillet. I'll try to get a picture of the completed speaker system, in place. The welder is a 350 Miller Syncrowave, with all the bells and whistles, circa 1989. The PVC tubes on the wall behind the welder contain filler rods for the TIG. The Argon bottles are 300CFt size. The truck is 'Old Ugly" Oo. GregH

 

[THenningsen]

can you guys tell me what these leads are in the picture? I notice there is no ground clamp or electrode holder. Do these leads go with this machine?... cause they don't look anything like the ones on miller's website. thanks for the help.



http://cgi.ebay.com/Miller-Thunderb...yZ113743QQssPageNameZWDVWQQrdZ1QQcmdZViewItem

 

[GHarman]

TH, Those seem to be twistlock quick disconnects on both leads. You have your ground clamp and electrode holder on another set of cables with the matching half of the QD on the opposite end. GregH

 

[THenningsen]

thanks Greg... are those an upgrade then?

 

[GHarman]

I would say so. They do not come with the machine and allow you to use different size cables and larger or smaller electrode holders and a short section of smaller welding cable ( whips ) matching the amperage range of a specific rod family, depending on what you are doing. It also allows you to disconnect or add longer leads as needed without connecting and disconnecting at the pole locations on the machine. GregH

 

[THenningsen]

well, I ended up finding a used miller thunderbolt xl ac/dc stick welder. Now I need to wire a 220 plug in my garage. Would you all go with anything other than 6-3 wire to do it? I was going to use #6, 3 strand wire with a ground and a 50amp breaker. Also, what size wire should I use for an extension cord?

 

[rbattelle]

well, I ended up finding a used miller thunderbolt xl ac/dc stick welder. Now I need to wire a 220 plug in my garage. Would you all go with anything other than 6-3 wire to do it? I was going to use #6, 3 strand wire with a ground and a 50amp breaker. Also, what size wire should I use for an extension cord?

Good choice with the 6-3 wire. Wish I'd done that - I used 10-3, which is good only to 30 amp.



Here's an ampacity chart. For 70A extension cord, McMaster likes 6 ga 4-conductor service cord ($8. 06/ft). I'd get at least 10 ft. This is nice stuff - very flexible. Check out their website, I notice they've added a convenient menu system for selecting the appropriate cable.



Ryan

 

[opjohnny]

I used 6-3 for mine. 50 amp breaker also. 100 amp was to expensive. My welder called for 8-3 and the 100 amp breaker.

 

[MrWinkey]

Wow I never got into this area of the forum!



I've been welding in the hobby/shop arena for 2 or 3 years now. I dont have the time to take classes at the local community college but I've been luckey enough to be able to get time with the Miller rep now and agian so he can show me what I'm doing wrong and what I need to pratice on.



I mostly do TIG but some MIG. Synchrowave 180 and a 251 w/ a spoolgun.



Anyway I'm going to go back to work but I'll be reading though all the previous pages of this post when I get home... . I only made it to page 5!

 

[GHarman]

MrWrinkley, There are a number of welding related Threads in the Shop Forum. There are also many TDR members that are excellent Welders, that can answer questions that you may have. I hope you find the information and help you need. Just ask. The only stupid question is the one that was not asked! GregH

 

[THenningsen]

Greg- I finally got my welder hooked up and burned my first rod. Wow, I suck!!!! My question is about amp settings. My welder is a Miller thunderbolt ac/dc stick welder. Should I be using ac or dc primarily. From my understanding DC is a little easier and will provide a little more penetration (DCEN). Also, I should use AC in the event I had a magnetized piece of metal, which would prevent arc blow, right? So, would you recommend using DC a majority of the time? The books I've read talk about amp setting when just starting out but they are all using an AC only machine. Looking at the front of my welder, it looks like there are two different amp scales. For example 120 amps on the AC side, translates to only 80 amps on the DC side (or something like that, i'm not looking at the machine right now). So, what amp setting do you recommend starting out on. Right now, I have a couple of pieces of 3/8" plate that I am practicing on and some 6010 and 7018 3/32 rods. For the time being my welding will be limited to improving my ability to maintain an arc and to lay a decent straight bead, so what rod, rod size, and amp setting do you suggest. Thanks so much for your help.

 

[rbattelle]

THenningsen, I won't even attempt to answer your questions - better leave that to someone who actually knows what he's talking about.

But, I have found the Miller Stick Calculator a good guide to the current range to use given an electrode diameter.

As everyone told me when I started, it just takes time. It can be occasionally frustrating, but man is it fun.

Ryan

 

[opjohnny]

Mr Winkey I have a 180 also. THenningsen we always used DCEP/DCRP when we stick welded. You have 2/3 the heat at the electrode in that situation. You can use DCEN/DCSP when using a 6012 rod on a lap joint. You might use ac in a vert up situation if you are having trouble with arc blow or wander or if welding aluminum(helps melt the oxide). Some rods are dc only so watch that. If I miss anything Greg will catch it. Hope this helps

John

 

[opjohnny]

Hey try 40-70 with that 6010 and 70-100 with the 7018 3/32. Those #'s are from my Lincoln book. We burned more 1/8" rod in class starting 90 amps on the 6010 and 120 for the 7018.

 

[GHarman]

THenningsen, Sorry it took so long to get back to you. First "Q". DCEN? Both 6010 and 7018 run best with DCEP ( Reverse Polarity). Second "Q" 3/32" 7018 runs well in the 75A-90A zone. BTW, a comparable setting for 1/8" 6010. 3/32" 6010 is as opjohnny says; 40-70A. The reason for the wide range of suggested settings is that there is allowance for cold metal ( ambient temperature ) Preheated metal and different thicknesses. Dont get confused. Take it one step at a time and you will be well on your way. You know the 7018 is running perfect when the flux curls up and away from the cooling weld an you progress with your bead. Dont panic if it doesn't. Just something to look forward to. Hold an arc length of about one rod diameter ( ex; 3/32" rod, 3/32" arc length. Hand eye coordination and muscle control is what you are also trying to learn. ( Multitasking Oo. ) Another thing, there are 7018 rods that are designed to run on AC. Sometimes you will find yourself in a position that requires a over amperage approach such as burning out entraped slag with one size smaller rod with no amperage adjustment. Or an increase in amperage to get that overhead weld. ( Depends on the situation ) As you learn you will also learn time saving methods that do not decrease the quality of what you are doing. Hope this is helpful. GregH

 

[GHarman]

THenningsen, One of the first welding exercises is stringer beads on plate. Make 'em straight and parallel sided. When you can do that try making a pad. A series of interlocking beads that half overlap the previous bead. Dont worry about weaving until you can do stringers and interlocking stringers. Greg

 

[JStieger]

I just wanted to say that this thread really inspired me to follow my dream of learning how to weld. I started taking a Welding 1 SMAW class at the local college once per week for 3 hrs per class until May. It makes for a really long day after my day job, but it's highly therapeutic :-laf !

 

[GHarman]

I just wanted to say that this thread really inspired me to follow my dream of learning how to weld. I started taking a Welding 1 SMAW class at the local college once per week for 3 hrs per class until May. It makes for a really long day after my day job, but it's highly therapeutic :-laf !

Good fer you. There is alot to learn! Take it one step at a time. You will be doing X-ray quality work before you know it. There is a HUGE demand in industry for SKILLED and Qualified Weldors. It Pays Good ,too! Remember to learn about protecting your health as you learn to weld, including Respiritory, Eye, proper lifting techniques, tools, and the word NO ( with an explaination and your SAFE method of getting the job done). Have a great timeOo. ! GregH