Hear, hear! This is basically all the welding I have done, except usually rusty steel with a flux core MIG! All I care is did the damned stuff stick together and can I grind it down enough to be presentable if necessary? I've stuck a lot of dead exhaust systems back together that held for years.
Yes... the experts make it look so easy..... I'm still learning to control my puddle size properly and get the filler in there at the right time. I have a job at the moment that is quite critical and involves laying on some edge beads on metal less than 1mm thick (about 30 thou actually)..... So far so good, I haven't burned anything but I'm using less than 20 amps..... For really small stuff I have used .8mm Mig wire for filler.... works a treat. Hopefully I can develop the skill before I fall off my twig (nearly 78 now!)...... Great video. As other have said it's nice to know that the experts bodge it up on repair jobs.....
something I didnt quite realize until someone pointed it out really, when I finally got a decent mig I was really pushing to stack dimes and have amazing welds every time just like dad did (he is however a sheet metal fabrication engineer and has been for 30 odd years...the last time i saw him with a torch in his hand i was 10 so....yeah...) i was making jigs and frames and all sorts of stuff that i had big plans for and scrutinized every single weld. It wasnt until my lovely wife pointed out to me that I am NEVER going to see any of these welds again unless i look for them so surely its far more important to get a weld that is solid rather than pretty to look at. From the mouths of babes right? remember penetration over perfection at first and if it's something you're doing for yourself (or favor for a friend i guess) you can always just grind it down anyway
My welding instructor advised this exact method. It’s only frowned upon when high tensile strength is required from the weld.... and this is a muffler, not a skyscraper
Justin, as always, your videos are very helpful. Not contrived, not too worried about beauty when it’s not needed. But workmanlike welding is what people need to see, and to understand, and you do it very well.
Sometimes you can use your chinese cold welder and a bit of 308 rod to tack this kind of stuff. Also you can use bass guitar strings that contain high quality steel core and nickel wounding. It forms quite strong weldings.
This has been so helpful in letting me know what I am doing has been in a way correct. I work in a factory that has given me a crash course in TIG and I have to patch mig welds that leak in pressure testing. A lot of my burnthrough patches look terrible but will hold. Using that bridge technique I think I can make them look much better. Thank you.
I was thinking Co2 just cuz thats wat i do with gas tanks i weld. Usually usually because theres spots like that paper thin and rusted out. I dont purge them tho i keep it running in the tank when i weld it hoping it displaces the gas fumes. Idk that it helps the weld any, but i havnt blown one up “yet”. Lol. But i use that stuff to shrink bearing races too. But try not to cuz i need it for the kegerater. Hahahahaha
Good job Justin, talk about making a "silk purse out of a sow's ear ". You succeeded ! It is right up there with doing a plumbing repair on an old house. No matter how careful you are, once you touch a section, the next is likely to break or leak. At least that pipe will see more service. The scoot probably has other issues. Even Harley dealerships usually refrain from working on older bikes because of the probability of CRAP happening. RIDE ON ! J K
I did the same thing welded up a 1970's motorcycle exaust left it on the bike to insure it would fit. Pipe broke off at the reduction like yours. I did not use tig, I used 6011 on a busbox at 45 amps like you, you weld on the previous weld untill the gap fills in. That was about 2 years ago and is still working. As for the heat cycles it kills everything over time. Cheers
I’m currently making a fabrication video collection of your videos to help me get going with learning to weld, love watching these videos you make it seems straight forward unlike a lot of other channels who like to get abit too in detail. Thanks a lot great work
I've been using a cold welder.. I got into that about 3 months ago.. and seriously I don't know how I can live without it at this point... It makes jobs like that, extremely easy.
The other magical thing, is if the customer is willing to pay (or if it's your own project) welds like that can be ground or sanded down to look like they were never there- thats the beauty of TIG, it really blends the filler into the base material (especially on aluminum and mild steel). Awesome work showing how quickly this job can get done!
Dude this video was bloody mint. Tons of variation and the narrations was choice. Not talking fast. I didn't have ti change the play speed to 75% on this one. And it was very enjoyable. Thank you.
My third time grabbing a tig torch I had to weld a rusted connection in an engine coolant system, the steel was very thin and I bloobed it and used the torch to massage it to shape, I thought I was using the stupidest techniques, but apparently my intuition was right. Loved the vid, Great shots
If it's breaking in the same spot, put a sleeve inside to re-enforce it. Welding very thin metal cooks the material to a point that it heat treats it and make it harder but brittle.
10/10 backing sleeve. It’s just going to break again. You can tell by how it is. Use a small sanding drum to remove bumps/ buildup inside the pipe, cut a piece of new exhaust pipe, maybe 1” or 1.5” slip it inside, weld away!
I was trained as an oxy-acetelene gas welder which is great for those sort of jobs but I now tend to use MIG on a low setting with 0.6 wire. As TIG is so similar to gas welding, I must get around to doing it. My welder has both MIG and arc terminals so i really ought to get to grips with it. Great little vid!
Dang you! Now I want to go out and get me tig welder. I didn't know this channel was gonna cost me money, lol Thanks good stuff and love the channel. Cheers from Motown.
I'm using 2.6mm stick weld to fill 1" hole on 1mm thin metal before i own tig weld. it's kinda difficult. later I'm using tig and realized how easy it is!
I'm brand new to this, just bought a stick welder and started making troll boogers just to get a feel for it. Pushing the puddle around is a real thing, it just started to click the other day. Cool stuff.
Thank you for being down to Earth and be able to show and admit even pros do make mistakes. I get frustrated with my welds from time to time as they are not pretty but does the job. This video gives me hope and motivation... thank you!!!
5 лет назад
Could you ground down the welds to smooth them out....some? Over 40 years ago as an apprentice in the steel fab division at a major shipyard, I rotate through the Shop Fitters. Easy work putting small steel fabrications together like vent trunks & hoods, foundations, brackets....etc. Was certified as a stick tac welder to hold them together for final welding. My 1st job was to assemble a vent hood for a commercial ship. A welder then welded all the joints. Afterwards, my supervisor told me to clean up the welds. He meant splatter. I didn't know. I took a H.D. wheel grinder and smoothed all the welds, such that it looked like one solid piece of metal. I was so proud of my work. My supervisor laughed and said it'll be OK for commercial work.
i did a repair on some dirty leaf thin stainless with 1.6mm sticks on a stick welder. it was crazy difficult, mainly cause i really couldn't see what i was doing due to where the hole was situated behind an electric motor. i was about 1 cm thinner than the hole i crawled in to to reach the rupture and i had to burn the sticks to about 10cm to be able to reach the part i was welding. i personally love these jobs, the challenge keeps me on my toes and because the equipment is important do i have about as much time as i want to ensure a good repair.
Justin, this is the kind of thing us welders see everyday that people want us to fix! A big thank you for showing us how its done. I buy Jody's T shirts and wear them everywhere. In fact I have his shirt on now with holes and rips in it. I hope you come out with a really cool T shirt too, because I will buy 2 or 3 and wear it everywhere also! PS did you use ER70-S2 filler? Thanks, Phil
Love the videos thank you! One question though... Is that a crazy amount of stickout? I'm still learning and I thought the stickout was supposed to be like half the diameter of the cup or something like that. I'm not being a jerk, just trying to learn and understand.
He’s running a gas flow lens and dumping a massive amount of argon, it helps with visibility and filming. The way you’re talking about is to use a conservative amount of argon without a gas flow lens.
This actually helped. Not the technique since Im trying to weld a small 12mm pipe (about 2mm thick though), and I messed it up royally. (I do have a broken spine, and since, my hands shake something else, add a freezing garage...good times). But seeing your welds hold but not looking pretty actually gives confidence. So many channels focus on pretty welds, that its like those how to play guitar videos from the 80s, with guys shredding (Michael Angelo Batio..Im looking at you!). So thanks.
Looks like I already commented LOL. Well...Im about to tackle some nasty rusted sheet metal welds today. The sanding along blew holes in it...so, yay, more stuff!
Welding rusty paper is a pain. I don't have a tig machine and my first mig is from Harbor Freight. But I still was able to weld up cracks in the exhaust header on my s-10 twice. I also had to make a patch for a quarter six hole. Thanks for the tips and commentary advice. It will help even on heavier stuff because almost all ranch repairs are on extremely rusty and rotted through metal. And most of my welding is done with a 20 year old Miller stick machine and 6011 rod.
I did a job like this recently, I used the " tack" method, lay down a row of spaced out full penetration tacks , then repeat overlapping each one until the joint is filled, the heat input is then minimal. If needed you can put another cap weld on top of the original tacks.
The better way to fix it (if you don't mind the color and aren't just going to replace it) is actually to braze it. The bronze is a lot better at filling all the little gaps and cracks and even flows in behind it if you do it right. Plus it is far better at dealing with heat cycling than regular filler rods, which is why Hooker still uses it on all their header flanges to this day.
You could put a T and needle valve after your regulator and use it as a purge hose fill one end with hose and something to keep gas leaking out, then tape off other end and put a few small holes in with a sharpened filler rod, adjust gas flow (by holes) so you can feel it leaving the holes and not the repair location. It will make filling in better and prevent the sugaring you saw inside the pipe from an earlier repair. It is basically a double gas purge on both sides of the weld. Can come in handy on thin materials and stuff you want to look nice. Run yourself a few coupons and see the difference in welding thin pipe, you want the flow to come mostly out your holes in taped end and not the repair location, no pressure just shielding gas presence. I always set up my gas regulators that way, with a small isolation valve in front of the needle valve so I do not damage the seat using it as a shut-off valve.
Heck yeah those look good especially considering what you were welding I’m trying to get that experience in and your vid’s help me a lot thanks for real
Nice work … Love the collection of Welding Machines. Have used most , Fronius, CIG, Lincoln, Liquid Arc etc. My Favourite was a Thermal Arc Inverter … It was a small unit similar to the ones behind you. It could do everything including Tig, Stick & Mig. 200 amp with minimal duty cycle restrictions. Smooth as silk to work with. Fronius Mig only were the standard in our workshop. 25 x 400 amp 40% Duty cycle. Great machines. Just the TA was tiny but could do the same work plus more.
I am a farmer and a self taught welder. I have used this technique for many years. I use an old arc welder and Baling wire as my filler rod. It melts in quicker than the actual welding rod. You end up using lots of wire to weld.
I always wonder how any harley part can stand up to the vibrations they put out. Good vid im really trying to step up my welding on a few projects at home , your series is giving me results...cheers from Australia.
Hello there from Thailand. I'm loving your videos. Keep up the great work and can you link me to one of you beginning tig basics, please. I'm looking to buy one but don't know what to look for and some tips, thank you
Ok, your newest sub. It’ll work. All I need now is patience, practice, and experience,,,,,, oh and a tig set up for my miller ac dc. Good video. My patches on the pipe would have looked like boogers with my mig on fatigued thin pipe. I will be watching this multiple times for sure. 👍
Sounds like the type of thing my dad or uncle would have said. My dad worked for IC railroad as a carman where they repaired and maintained all kinds of railroad cars and equipment and went to derailments. He learned a lot of his skills on job but he also was a motorcycle racer when younger and did a lot of welding with that and he always worked on his own vehicles and was always doing welding on all kinds of projects. I always wished i had taken the time to learn more from him on welding and practice with him.
I'm not a professional welder but have been around the block. What about fabricating a circular band, say 1/2" wide or more that would be pressed into the pipe half way and tacked, then the other piece forced over the internal band. The metal could be a slice of tubing or even 18 ga or more sheet metal formed into a band. That would add to the thickness, a backing plate so to speak. I kind of doubt it would cause any change in performance of the pipe. Jim
I had an old Ford Courier and one spot that had almost no frame left. We cheated and I took some ten inch nails and tacked them in and then filled in around them. That was with an Arc/stick welder though. It worked great.
I was Welding Two small Motor header Flanges For a Custom ( Vanguard Cushman Conversion ) Last night The Pipe was Was Very thin and the flanges are like 3/8” thick and were Very Hard and considerably thicker than the pipe........! I am a So So welder, for probably over 50 years...! I have a new harbor freight tungsten 125 flux core Inverter wire welder that does a fantastic job...! ( ON ONE THICKNESS OF METAL AT A TIME...! ) The problem I had was it took more heat to make the Weld stick to the thicker heavier flange than it took to make the weld stick to the thin exhaust pipe....! And when the welder would run a nice bead on the flange it was too hot for the pipe and would blow holes through it...! I knew this would be a problem before I started , the flanges did not fit over the pipe they just Butted up against the hole....! So I took both flanges with a step bit and made the whole large enough for the pipe to slightly countersink halfway through the flange....! This did help but when you would bring a Nice Looking bead too close to the Flange , that he would still blow a hole through the pipe....! What is the trick for welding a cooler metal to a thin metal without completely totaling out the thin metal once the bed is running......??? Thank you Professor Jeff..🎵🎹🎸🎻🎶🎓 PS I did get them welded they are not pretty like you said but they are strong I did have to actually put a small patch next to the flange area to make my exhaust pipe thicker the same to work well....!
wondering y ur tungsten was sticking out so far from the cup? usually don’t u want no more than 1/4” stickout from the cup for proper gas coverage? u might hav had an easier time welding with a shorter stickout imo
Probably a stupid question, but why so much stick out and the large cup for this particular job? Not a professional welder and working on my TIG (your stainless guide reassured me on some things to get a job done while my welder was out of town), so always trying to learn.
I had to learn this hole filling technique not too long ago. Because making pie cuts with a reciprocating saw and your foot to hold the pipe isnt the best way to go about doing that. Used a 110 mig though.
Not to nitpick, but you forgot to mention the all-important dwelling over the end of the weld with your isolation gases so you don't develop porosity. I understand that you know this all too well - I can see you doing it in the videos, but there might be some viewers that don't know that. Porosity sucks that much more when its in thin-guage sheet metal. It can cause cracks in the exhaust, which would inevitably lead to it breaking again, no matter how good the rest of the weld turned out.
Would of been very tempted to make a sleeve to go inside that join and weld both sides to it? The sleeve would take some of the load stress away from the weld. Always tough when you not exactly sure what material you welding. Good work on a tough job.
The Fabrication Series will do. Big fan of your work mate. Just keeping it real,sharing your knowledge and enthusiasm and inspiring others. I love welding, just when you think you got it all sussed out a job comes along that proves you never stop learning! Great videos to watch even for non welders!
The customer SHOULD have brought ,and demanded it be inserted, a thin "sleeve", just a strip of steel 1/2x 1/32 or even 1 mm,made circular around that same pipe,small gap at ends,ok; i would have.
I tend to overheat the crap out of the material when I’m doing work like this. Could you do a video on how to repasify stainless to regain stainless properties after weld work? For food equiptment work?
Got lots of practice filling holes this week trying to put two different “304” stainless kegs together for an offset smoker. One keg was definitely not 304 and would just seem to ‘burn’ away at times and make a huge hole. Great practice, disgusting looking welds, but they are held together! Who knows how the crappy keg will hold up as a fire box however...
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Did you use weld thru primer?
TFS I'm a professional hole maker
in thin metal !!!!!!!!!! Thanks for the vid .......
what kind of welder is this??? i would love to get one???
@@alberthendershot3134 LMFAO
@@haroldwitham2038 lol he's got a bunch
I am a welding instructor with many years of experience. This video is GREAT! Very professional and realistic fix
"All we really need to do is just make them hold" - Best welding advice ever ;-)
Too many beginners are expecting to stack dimes!
Right cant stack dimes without experience and cant stack them on everything u weld some things are are quantity over qulity or time or quality
Hear, hear! This is basically all the welding I have done, except usually rusty steel with a flux core MIG! All I care is did the damned stuff stick together and can I grind it down enough to be presentable if necessary? I've stuck a lot of dead exhaust systems back together that held for years.
Yes... the experts make it look so easy..... I'm still learning to control my puddle size properly and get the filler in there at the right time.
I have a job at the moment that is quite critical and involves laying on some edge beads on metal less than 1mm thick (about 30 thou actually)..... So far so good, I haven't burned anything but I'm using less than 20 amps..... For really small stuff I have used .8mm Mig wire for filler.... works a treat.
Hopefully I can develop the skill before I fall off my twig (nearly 78 now!)...... Great video. As other have said it's nice to know that the experts bodge it up on repair jobs.....
I stacked dimes my first try, on stick. On the harbor freight wire, i was laying booger city
something I didnt quite realize until someone pointed it out really, when I finally got a decent mig I was really pushing to stack dimes and have amazing welds every time just like dad did (he is however a sheet metal fabrication engineer and has been for 30 odd years...the last time i saw him with a torch in his hand i was 10 so....yeah...) i was making jigs and frames and all sorts of stuff that i had big plans for and scrutinized every single weld. It wasnt until my lovely wife pointed out to me that I am NEVER going to see any of these welds again unless i look for them so surely its far more important to get a weld that is solid rather than pretty to look at. From the mouths of babes right?
remember penetration over perfection at first and if it's something you're doing for yourself (or favor for a friend i guess) you can always just grind it down anyway
I learned that technique by myself, i though it was a little sketchy but now that i saw a pro doing it i can relax
Same over here😂😂
Same here.. I'll do a really cold weld with a lot of filler.. cover it all up, and the just run the torch over it to make it blend in
My welding instructor advised this exact method. It’s only frowned upon when high tensile strength is required from the weld.... and this is a muffler, not a skyscraper
Exact same here and I first learned it with a MIG at that lol. Still use it today on both Mig and now Tig.
this is my favourite video. it mirrors the kinds of challenges I face as a restoration hobbyist
Justin, as always, your videos are very helpful. Not contrived, not too worried about beauty when it’s not needed. But workmanlike welding is what people need to see, and to understand, and you do it very well.
"Massive pile of snot" is my new favorite technique in welding!
Low amperage MPS technique.
You should try acrylic welding. Create a massive pile of snot then smooth over with acrylic and paint. Does not work with mufflers though.
Sometimes you can use your chinese cold welder and a bit of 308 rod to tack this kind of stuff. Also you can use bass guitar strings that contain high quality steel core and nickel wounding. It forms quite strong weldings.
Clear instruction from someone with experience and genuine enthusiasm. Well done, interesting, and fun to watch.
So fun to watch people who have no idea of what they are doing yet trying to explain things like they have some great understanding.
This has been so helpful in letting me know what I am doing has been in a way correct. I work in a factory that has given me a crash course in TIG and I have to patch mig welds that leak in pressure testing. A lot of my burnthrough patches look terrible but will hold. Using that bridge technique I think I can make them look much better. Thank you.
The wonderful thing about Tiggers, and Tiggers is wonderful things, They can weld everything but rubber and you really shouldn't weld springs.
At last, an honest representation of what's need to make it work! Good job!
I'm more of a grinder than a welder so I appreciate showing the not beautiful stuff that works.
That's how I've always done it.
You should try purging the pipe with argon. Works well
I was thinking Co2 just cuz thats wat i do with gas tanks i weld. Usually usually because theres spots like that paper thin and rusted out. I dont purge them tho i keep it running in the tank when i weld it hoping it displaces the gas fumes. Idk that it helps the weld any, but i havnt blown one up “yet”. Lol. But i use that stuff to shrink bearing races too. But try not to cuz i need it for the kegerater. Hahahahaha
Good job Justin, talk about making a "silk purse out of a sow's ear ". You succeeded ! It is right up there with doing a plumbing repair on an old house. No matter how careful you are, once you touch a section, the next is likely to break or leak. At least that pipe will see more service. The scoot probably has other issues. Even Harley dealerships usually refrain from working on older bikes because of the probability of CRAP happening. RIDE ON ! J K
I did the same thing welded up a 1970's motorcycle exaust left it on the bike to insure it would fit. Pipe broke off at the reduction like yours. I did not use tig, I used 6011 on a busbox at 45 amps like you, you weld on the previous weld untill the gap fills in. That was about 2 years ago and is still working. As for the heat cycles it kills everything over time. Cheers
Novice welder here. Thanks for a straightforward tutorial.
I’m currently making a fabrication video collection of your videos to help me get going with learning to weld, love watching these videos you make it seems straight forward unlike a lot of other channels who like to get abit too in detail. Thanks a lot great work
I did this with a Mig in 10 mins and it looked great. This was on a Stainless Steel Exhaust for a large camper van. Customer was well happy!!!
I've been using a cold welder.. I got into that about 3 months ago.. and seriously I don't know how I can live without it at this point... It makes jobs like that, extremely easy.
The other magical thing, is if the customer is willing to pay (or if it's your own project) welds like that can be ground or sanded down to look like they were never there- thats the beauty of TIG, it really blends the filler into the base material (especially on aluminum and mild steel). Awesome work showing how quickly this job can get done!
building up around a hole and filling it in is an art form all in its self, sweet video
I'm so glad I found this channel! I started taking welding classes in college, but I feel like these videos clear up most of my random question.
Dude this video was bloody mint. Tons of variation and the narrations was choice. Not talking fast. I didn't have ti change the play speed to 75% on this one.
And it was very enjoyable.
Thank you.
Can You Learn this from RUclips Do you normally change the speed?
Excellent! Great video. Very refreshing to watch a no nonsense tutorial that is also fun to watch. Beautiful. I've subscribed.
My third time grabbing a tig torch I had to weld a rusted connection in an engine coolant system, the steel was very thin and I bloobed it and used the torch to massage it to shape, I thought I was using the stupidest techniques, but apparently my intuition was right. Loved the vid, Great shots
If it's breaking in the same spot, put a sleeve inside to re-enforce it. Welding very thin metal cooks the material to a point that it heat treats it and make it harder but brittle.
My thoughts exactly and repaired many items this way
Right Rolando. I was wondering about why this was not done. or cut out the bad area and splice in a new piece of metal.
10/10 backing sleeve. It’s just going to break again. You can tell by how it is. Use a small sanding drum to remove bumps/ buildup inside the pipe, cut a piece of new exhaust pipe, maybe 1” or 1.5” slip it inside, weld away!
Or sell the Harley and buy another brand bike. LOL
Why don't you just anneal it then?
I was trained as an oxy-acetelene gas welder which is great for those sort of jobs but I now tend to use MIG on a low setting with 0.6 wire. As TIG is so similar to gas welding, I must get around to doing it. My welder has both MIG and arc terminals so i really ought to get to grips with it. Great little vid!
Dang you! Now I want to go out and get me tig welder. I didn't know this channel was gonna cost me money, lol Thanks good stuff and love the channel. Cheers from Motown.
I'm using 2.6mm stick weld to fill 1" hole on 1mm thin metal before i own tig weld. it's kinda difficult. later I'm using tig and realized how easy it is!
I'm brand new to this, just bought a stick welder and started making troll boogers just to get a feel for it. Pushing the puddle around is a real thing, it just started to click the other day. Cool stuff.
Thank you for being down to Earth and be able to show and admit even pros do make mistakes. I get frustrated with my welds from time to time as they are not pretty but does the job. This video gives me hope and motivation... thank you!!!
Could you ground down the welds to smooth them out....some? Over 40 years ago as an apprentice in the steel fab division at a major shipyard, I rotate through the Shop Fitters. Easy work putting small steel fabrications together like vent trunks & hoods, foundations, brackets....etc. Was certified as a stick tac welder to hold them together for final welding. My 1st job was to assemble a vent hood for a commercial ship. A welder then welded all the joints. Afterwards, my supervisor told me to clean up the welds. He meant splatter. I didn't know. I took a H.D. wheel grinder and smoothed all the welds, such that it looked like one solid piece of metal. I was so proud of my work. My supervisor laughed and said it'll be OK for commercial work.
Thank you for encouraging my current repairs.
i did a repair on some dirty leaf thin stainless with 1.6mm sticks on a stick welder. it was crazy difficult, mainly cause i really couldn't see what i was doing due to where the hole was situated behind an electric motor. i was about 1 cm thinner than the hole i crawled in to to reach the rupture and i had to burn the sticks to about 10cm to be able to reach the part i was welding.
i personally love these jobs, the challenge keeps me on my toes and because the equipment is important do i have about as much time as i want to ensure a good repair.
Justin, this is the kind of thing us welders see everyday that people want us to fix! A big thank you for showing us how its done. I buy Jody's T shirts and wear them everywhere. In fact I have his shirt on now with holes and rips in it. I hope you come out with a really cool T shirt too, because I will buy 2 or 3 and wear it everywhere also!
PS did you use ER70-S2 filler? Thanks, Phil
The quality of the videos, as well as content is amazing. Thank you for the videos.
Thank you for the good video of this repair. Always very interesting to see a pro at work who tells you what he is doing.
Love the videos thank you! One question though... Is that a crazy amount of stickout? I'm still learning and I thought the stickout was supposed to be like half the diameter of the cup or something like that. I'm not being a jerk, just trying to learn and understand.
He’s running a gas flow lens and dumping a massive amount of argon, it helps with visibility and filming. The way you’re talking about is to use a conservative amount of argon without a gas flow lens.
This is why I love tig welding.
Control is beyond imaginable.
nice save!!! not every weld is going to be as pretty as we like them.
some of the prettiest and best welds i have ever made will never be seen
This actually helped. Not the technique since Im trying to weld a small 12mm pipe (about 2mm thick though), and I messed it up royally. (I do have a broken spine, and since, my hands shake something else, add a freezing garage...good times). But seeing your welds hold but not looking pretty actually gives confidence. So many channels focus on pretty welds, that its like those how to play guitar videos from the 80s, with guys shredding (Michael Angelo Batio..Im looking at you!).
So thanks.
Looks like I already commented LOL. Well...Im about to tackle some nasty rusted sheet metal welds today. The sanding along blew holes in it...so, yay, more stuff!
Most real world weld advice/demo ive seen yet. Thanks and well done!
Welding rusty paper is a pain. I don't have a tig machine and my first mig is from Harbor Freight. But I still was able to weld up cracks in the exhaust header on my s-10 twice. I also had to make a patch for a quarter six hole. Thanks for the tips and commentary advice. It will help even on heavier stuff because almost all ranch repairs are on extremely rusty and rotted through metal. And most of my welding is done with a 20 year old Miller stick machine and 6011 rod.
Patience is a useful virtue in successful welding. Taking time to prepare and setup is crucial to success!
I did a job like this recently, I used the " tack" method, lay down a row of spaced out full penetration tacks , then repeat overlapping each one until the joint is filled, the heat input is then minimal. If needed you can put another cap weld on top of the original tacks.
The better way to fix it (if you don't mind the color and aren't just going to replace it) is actually to braze it. The bronze is a lot better at filling all the little gaps and cracks and even flows in behind it if you do it right. Plus it is far better at dealing with heat cycling than regular filler rods, which is why Hooker still uses it on all their header flanges to this day.
i've been doing that without a foot pedal cuz i cant get one for my machine, but the technique still the same, great video!
Kudos (Thank You) for displaying skill and method, rotating the exhaust and allowing it to cool and weld other parts is genius to prevent damage.
You could put a T and needle valve after your regulator and use it as a purge hose fill one end with hose and something to keep gas leaking out, then tape off other end and put a few small holes in with a sharpened filler rod, adjust gas flow (by holes) so you can feel it leaving the holes and not the repair location. It will make filling in better and prevent the sugaring you saw inside the pipe from an earlier repair. It is basically a double gas purge on both sides of the weld. Can come in handy on thin materials and stuff you want to look nice. Run yourself a few coupons and see the difference in welding thin pipe, you want the flow to come mostly out your holes in taped end and not the repair location, no pressure just shielding gas presence. I always set up my gas regulators that way, with a small isolation valve in front of the needle valve so I do not damage the seat using it as a shut-off valve.
That job is definitely a test of any welders ability. I've run into similar situations on older cars,
Totally new to this welding. Enjoyed your video. Thank you for taking the time to teach and explain.
Struggled with this sort of thing before, very useful. Thank you.
Technique is similar to how I used to repair bike mufflers using my oxy/acet 45 years ago.
Nice and patient work, there.
Not sure how I ended up here - I'm not a welder - but this was interesting and informative. Cool vid sir, thanks :)
Welcome to the welding community, you should stay for a while we’re pretty nice
Heck yeah those look good especially considering what you were welding I’m trying to get that experience in and your vid’s help me a lot thanks for real
been doing something like this on thin stainless for years . same deal fatigued metal with impurities, and prior repairs. Gotta do what ya gotta do !
Nice work … Love the collection of Welding Machines.
Have used most , Fronius, CIG, Lincoln, Liquid Arc etc.
My Favourite was a Thermal Arc Inverter … It was a small unit similar to the ones behind you. It could do everything including Tig, Stick & Mig. 200 amp with minimal duty cycle restrictions. Smooth as silk to work with. Fronius Mig only were the standard in our workshop. 25 x 400 amp 40% Duty cycle. Great machines. Just the TA was tiny but could do the same work plus more.
I am a farmer and a self taught welder. I have used this technique for many years. I use an old arc welder and Baling wire as my filler rod. It melts in quicker than the actual welding rod. You end up using lots of wire to weld.
I always wonder how any harley part can stand up to the vibrations they put out.
Good vid im really trying to step up my welding on a few projects at home , your series is giving me results...cheers from Australia.
They dont. They fall off and break all the time that is why we are always fixing our harleys.
You sir are an artist.looks good to me .if it works that's what counts .keep up the good work.
Lots of help for people like myself trying to keep the pipes from 1970's rice burners functional.
Nice rescue! I like Your welding techniques, and Your educational skills! Thanks for sharing!
I TRULY appreciate your time and effort in making your videos. I bought your shirt. GBYAY....... Kenny in Vegas
I’m not a great welder - but a superb grinder!
Nice job man!
i use a similar technique at work for welding thick material to thin material, it is a fun thing to practice
i welded a 3 inch exhaust pipe for a truck, i used 3/32 7018 at 135 amps, i had to feed the stick fast, also had to use a way to strike a soft arc.
What I like about this video is that it is a real life situation not a coupon on the bench
Hello there from Thailand. I'm loving your videos. Keep up the great work and can you link me to one of you beginning tig basics, please. I'm looking to buy one but don't know what to look for and some tips, thank you
Cup brush on a cordless drill is what I’m stealing from this video thank you
Good job and great work Mr.Justin
Ok, your newest sub. It’ll work. All I need now is patience, practice, and experience,,,,,, oh and a tig set up for my miller ac dc. Good video. My patches on the pipe would have looked like boogers with my mig on fatigued thin pipe. I will be watching this multiple times for sure. 👍
You Never disappoint! I was curious how a pro does this and it was exactly how I did it the other week!
A pro would have made a thin steel insert to stabilize the pieces. It would never show.
Awesome watching you patch this fish tail pipe,I had one laying around so I retro fitted on a pit bike 👍🏻
I was taught by my grandfather to use a filler (coat hanger) when stick welding to fill in. And it works perfectly
Sounds like the type of thing my dad or uncle would have said. My dad worked for IC railroad as a carman where they repaired and maintained all kinds of railroad cars and equipment and went to derailments. He learned a lot of his skills on job but he also was a motorcycle racer when younger and did a lot of welding with that and he always worked on his own vehicles and was always doing welding on all kinds of projects. I always wished i had taken the time to learn more from him on welding and practice with him.
Cheers and thanks....starting in on some sheet metal repair on my old truck project and this helps!
I'm not a professional welder but have been around the block. What about fabricating a circular band, say 1/2" wide or more that would be pressed into the pipe half way and tacked, then the other piece forced over the internal band. The metal could be a slice of tubing or even 18 ga or more sheet metal formed into a band. That would add to the thickness, a backing plate so to speak. I kind of doubt it would cause any change in performance of the pipe. Jim
Great how to. Still a novice, however as a motorbike enthusiast . I will come across scenarios like this fairly often.. . Subbed Awesome channel..
Sweet, just what I needed to fix the holes I made on the edge pieces trying to tig .083 mild steel tubing!
Excellent Video Skills, and Great Explanation of Your Technics!!
This is a great presentation of a tough subject (at least, for me). Thank you!
I had an old Ford Courier and one spot that had almost no frame left. We cheated and I took some ten inch nails and tacked them in and then filled in around them. That was with an Arc/stick welder though. It worked great.
I was Welding Two small Motor header Flanges For a Custom ( Vanguard Cushman Conversion ) Last night The Pipe was Was Very thin and the flanges are like 3/8” thick and were Very Hard and considerably thicker than the pipe........! I am a So So welder, for probably over 50 years...! I have a new harbor freight tungsten 125 flux core Inverter wire welder that does a fantastic job...! ( ON ONE THICKNESS OF METAL AT A TIME...! ) The problem I had was it took more heat to make the Weld stick to the thicker heavier flange than it took to make the weld stick to the thin exhaust pipe....! And when the welder would run a nice bead on the flange it was too hot for the pipe and would blow holes through it...! I knew this would be a problem before I started , the flanges did not fit over the pipe they just Butted up against the hole....! So I took both flanges with a step bit and made the whole large enough for the pipe to slightly countersink halfway through the flange....! This did help but when you would bring a Nice Looking bead too close to the Flange , that he would still blow a hole through the pipe....! What is the trick for welding a cooler metal to a thin metal without completely totaling out the thin metal once the bed is running......??? Thank you Professor Jeff..🎵🎹🎸🎻🎶🎓
PS I did get them welded they are not pretty like you said but they are strong I did have to actually put a small patch next to the flange area to make my exhaust pipe thicker the same to work well....!
What u talking about? That is a beautiful job! Especially with what your working with. Do give welding classes?
Holy hell that's some serious stick out your using. Lol. Did you keep a 1" stick out just for the camera??
The great fupa 12. Love that cup
Love my Furick!!
You sir, are a true artist!
Great explanation of what you were doing and why.
I'm sorry, I just start learning to weld; what is that name of the tool you used to heat the area?
wondering y ur tungsten was sticking out so far from the cup? usually don’t u want no more than 1/4” stickout from the cup for proper gas coverage? u might hav had an easier time welding with a shorter stickout imo
Looks damn good. Old exhaust tubing is so easy to blow through, I'm amazed you could make the join.
been doing repairs like that in the field for years with an gas welder in between motos. cool video !!!
Probably a stupid question, but why so much stick out and the large cup for this particular job? Not a professional welder and working on my TIG (your stainless guide reassured me on some things to get a job done while my welder was out of town), so always trying to learn.
I had to learn this hole filling technique not too long ago. Because making pie cuts with a reciprocating saw and your foot to hold the pipe isnt the best way to go about doing that. Used a 110 mig though.
Not to nitpick, but you forgot to mention the all-important dwelling over the end of the weld with your isolation gases so you don't develop porosity. I understand that you know this all too well - I can see you doing it in the videos, but there might be some viewers that don't know that. Porosity sucks that much more when its in thin-guage sheet metal. It can cause cracks in the exhaust, which would inevitably lead to it breaking again, no matter how good the rest of the weld turned out.
Would of been very tempted to make a sleeve to go inside that join and weld both sides to it? The sleeve would take some of the load stress away from the weld. Always tough when you not exactly sure what material you welding. Good work on a tough job.
Andrew Wilson Check out my reply to another comment that mentioned the same thing.
The Fabrication Series will do. Big fan of your work mate. Just keeping it real,sharing your knowledge and enthusiasm and inspiring others. I love welding, just when you think you got it all sussed out a job comes along that proves you never stop learning! Great videos to watch even for non welders!
Andrew Wilson I was thinking the same thing, I have seen sleeves used on hand rails to reinforce the joint,
The customer SHOULD have brought ,and demanded it be inserted, a thin "sleeve", just a strip of steel 1/2x 1/32 or even 1 mm,made circular around that same pipe,small gap at ends,ok; i would have.
Great job !!. What about dents in exhausts pre re-chroming.
I tend to overheat the crap out of the material when I’m doing work like this. Could you do a video on how to repasify stainless to regain stainless properties after weld work? For food equiptment work?
Got lots of practice filling holes this week trying to put two different “304” stainless kegs together for an offset smoker. One keg was definitely not 304 and would just seem to ‘burn’ away at times and make a huge hole. Great practice, disgusting looking welds, but they are held together! Who knows how the crappy keg will hold up as a fire box however...
That weld look great ! Good job not many would even try that job !