Welding thin steel tube with a stick welder
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- Опубликовано: 5 авг 2016
- If all you've got is a stick welder and you need to weld some 1.6 mm square hollow section, it can be done. This video shows a basic T joint using 6013 grade 2.5 mm rods I bought from a hardware store a long time ago. Current was set to 75 amps at 45 volts. Sure, it isn't pretty but the stop start technique means you don't blow holes through the steel in the process. If you're trying to pass a test and you're looking at videos, this one probably won't help. But for making a gate frame or work bench a humble stick welder can be made to work.
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‘The first rule of welding is to criticise everyone else’s welding’. Never a truer word was spoken. Thanks for the video mate, really enjoyed it.
Dang, isn't that the truth
To go along with some of the other good tips in the comments, here are one-and-a-half more suggestions. It's been mentioned that you can go with smaller electrodes and lower amperage. Here in the USA you can get E6013 in diameters as small as 1/16th inch. That stuff gives smooth performance at 30 amps and below.
Also, once you are working with an arc that's small enough and weak enough, manipulate that arc so it spends more time on the base-metal side of the joint. In this case the base metal is the tube section that includes the boxed corner. Spend much less time on the other side of the joint which is the piece that's the open end of the tube. As an example, count a steady "one-two-three-one-two-three-" and keep the arc on the base metal for "one" and "two", and swing across onto the end-tube metal for count "three", and swing right back again. When you swing across to the delicate side of the joint, you are just "carrying the puddle" across, rather than blasting the metal on that side. As the puddle coalesces with the metal on the delicate side of the joint, swing your arc right back to the 'safer' side again. Vary your counting speed and counting pattern as needed to get the right combination of heat on the corner metal compared to the open-end metal. You can include that start-stop method too if you are still exceeding the limits with a weak arc, but even then, your goal is to keep more heat on the base-metal side of the joint.
Learning how to fill your holes is part of the game, and with practice, you can get right to work filling a hole without ever stopping, with the right combination of sweeping the edges and even sweeping right across the gap.
I liked your nod to what it's like to be a beginner, with using a full-length electrode to being like "turning off a light switch with a broom handle." Practice practice practice!
Just researching for my first project, some excellent tips and guidance there.
Thanks and very much appreciated.
Eric L great advice Eric. I'm not familiar with the electrodes you mentioned. I will keep it in mind. Perhaps we don't get those welding sticks here. We now have Chinese imports. I will have to go to my shed to see the brands of welding sticks we get.
I bought high strength Welder's rod low hydration. They take a bit more to strike.
Also we get thinner welding rods.
That old welder is pretty good.
Great advice, “stick welders”’read and learn,thank you for passing on your knowledge.
Jim Alley thanks Jim. I did buy some low hydration welding stick which read 7016. They seem harder to initially strike although when they do make a beautiful weld. I was always buying standard welding sticks for mild steel. I will make a note what you mention as I feel the high strength welding sticks are better.
Thanks for the advice appreciated.
I did in the last buy better grade sticks 1.6 and 2mm. The main suppliers was cigweld although the other brand I got was weld boss I think.
Well explained, and the 3 key things you said there is definitely practice, practice and practice!!!
I butt welded two pieces of 1/8 “ flat stock today. I ground away all the excess weld and went to town trying to break it. I was shocked I couldn’t. Just sharing my success, nobody here cares.
I care Gene Miller :) I recently got myself to the same position. Feels great! Of course I then went on to try weld the tube I intended to weld and blew holes in it repeatedly so, not feeling as confident anymore
Michael Andersen keep at it Michael. Perhaps thinner welding sticks?
Gene Miller well done Gene. The people here who are enthusiasts do care and it's great reading others people's comments.
Do you want a hug, or do you need a cup of cement?
I say a job well done.
🖖😎
finally an Aussie that doesn't speak in inches and inch fractions!
finally, one more moronic metric troll, who just fixates on trivia
Still can’t figure out fractions eh?
I guess he must have an issue with fractions..... a large fraction of the time....
Imperial is shit, metric all the way
chris fricker ok boomer
When I first started welding back in 1985, I welded on 22 gauge steel. Thinner than what you are welding. I set the welder at 70 amps using a E7011 we had to weld without stopping, because the welds had to be grinned smooth, and painted. On thin tubing if you can not weld a full weld without stopping use a thick peace metal to absorb the heat. You can clamp it on both sides of the weld and never have a problem. Starting and stopping is not a good weld for withstanding the rating of the weld. I bet if you try welding this 1/8" tubing with two 1/4" steel plates clamped very close to your weld you will be able to weld it the correct way. Good luck.
mickey sanker What size E6011?
3/32. Also if the heaver metal plate keeps getting stuck you can use copper plates.
Intresting trick, sure i'll give it a go. Thanks for sharing the knowledge!
thank you for the tip
may i see the clamp look like i just dont understand sorry im new
Thanks for the vid. Every other welding video starts with "now grab a piece of half inch plate"
You have an incredibly steady hand and those were great welds on thin tube w a stick.
Super helpful!... looking to weld some square tubing for an upcoming project and an old buzz box is all I got right now:)
Joe
Hey glad I could help!
homesteadonomics
I
Me too.
mate your a legend been looking for somthing like this hopfully i stop burning holes
Yeah, me too!
Excellent stuff, worked like a charm! I was welding 1.6mm thick round tubes together end to end and I used this technique with 1.6mm rods at 38 - 40A. Great video, thanks very much!
These are good tips Chris. A pro welder in Moree gave me a few hints like this a few years ago. Looks like you've worked out that a shallow angle with the rod is the main thing. I'm only a backyard do-it-yourself type welder myself and need all the help I can get.Videos like yours Chris help a lot of us who aren't up with all the techniques. Good stuff Mate!
I am definitely going to try this technique! Thanks for sharing!
Respect from a bloke that needs all the advice and help he can get.
Thanks for making this vid. I was having a hard time with welding on thin stuff. Warming the stick up 1st off the side on something heavy was the thing I was missing.
me too Dick
Hi Chris! Thanks man! Just left the garage 10 minutes ago with a grin on my face. Was trying to weld some 1.5mm thick rectangular tubing but kept blowing holes through the material. Your suggestion worked!
I experienced the same as yours. Truly I'm disappointed of myself trying to build a railings in my house. It's 2018 april
Worked very well for me Chris, i have struggled for years with the thin walled tube but now able to produce much better results on my latest project. Thank you for the video !! Glen
From one Aussie to another, this was really helpful as I also have a project to do with thin tubing and I wasn't really sure how to approach it. Cheers!
Thank you Chris for this video. I was able to finish my project because of your direction.
I would have never thought it possible based on my limited experience with stick welding. Judging by the comments section a lot of folks appreciate your taking the time to do the video.
Thanks, this really helped me. I just started welding and for my project I had to weld 2mm steel tubes with 6013 2.5mm electrodes on an old transformer welder. With your technique I managed to make good welds without inclusions. On most forums/guides they tell you to lower the amperage but you will only get ugly welds with low amps.
After blowing holes in the round tubing I'm trying to weld, I came across your video. Thank you, I'll try your technique in the morning.
Perfect video mate!!!! Loved it!!! We don’t all have brand new welders, loved the Bunnings plug!!!!
Great for the backyarder!!!!
Thanks for doing this one. I've been trying to gain enough skill to restore my dirt bike trailer. It has the same thin square tube around the front.
Thanks for the tip, Chris. I've been burning holes on thin tubing. Now there's a solution.
Great video mate! Just a quick tip - the starting is easier not because the tip is hot but because the metal in the middle is exposed. To avoid ruining your ground clamp (like you did in the video), just break the coating at the very end of the rod to expose the metal... if you break too much you will have a little bit of harsh start, but it does the work! I have the pliers type rod holder and I just crimp the end of the rod with it - works every time!
Cheers!
Thanks, I found this out by accident, I just tapped the end of the rod with my hammer out of frustration because I couldn't strike an arc at all.
Thank you ! For me, this is the best tutorial on square tube stick welding.
Loved your video! Honest, direct and real.
Just completed my first project using the same square hollow section.. Blew holes on about half my welds and thought I had the wrong amperage setting (on the plus side I did manage to keep it square, strong & stable which surprised me). Wish I had watched your video first, some great tips. Looking forward to doing better on my next project! :)
Great work maestro!! Very good welding technique.Thanks
Just made my first food cart using thin square tube...I blow lot of holes...
Thanks Chris for this helpful technique....
Thanx for taking the time to produce and post this video. I like using patio tubing on jobs and there are only so many things you can use brackets for. I will re-watch this a couple of times and start practising
Just learning to weld at 60, thanks for helping to give me the confidence
I've seen other people use this technique but have never seen it on a video. Thanks for the tip.
I never thought I’d be looking for welding tips on RUclips and find I’m getting them from my little brother 🤦♂️
Bahahahaha!! Blind leading the blind :)
Chris Jones Right you pair! Stop your arguing and get outside before I get a broom to you both!!!
🤣🤣🤣🤣🤣
(65 here guys and still looking for tips, 😇 😊😊. Also got 4 brothers so well experienced with the buggers 😂😂😂😂)
Thanks Chris
Hi Chris, just what I was looking for, Thanks mate
The best stick welding technique found in youtube. I have to agree, honest and practical, do another your good at it
Can't tell you how many holes I made before I watched this. I'm not the sharpest tool in the shed. Thanks much for the great info I now am saving alot of time. Luca
You confronted 1.6mm like a champ with a digital welding machine. That ancient machine is a quality unit.
"If you're trying to pass a test and you're looking at videos, this one probably won't help. But for making a gate frame or work"
thank you
No gloves, no overalls. Proper Aussie welder. ;) (disclaimer: not suggesting you should NOT use gloves and overalls for safety - you should.)
That is completely wrong. While people can get away without using gloves and an overall, you should wear it. For one, it protects you from the rays. Then the obvious protection from berries which can drop down especially if you are doing odd angles. A thick leather glove will not burn through. Personally I use an old cotton military jumpsuit and some welding gloves.
You don't want synthetic protection around any heat as it will melt and stick to skin. I think that is what you were thinking of.
The ultraviolet light will affect his skin in later years. Radiation is not to be messed with and gloves and covering should always be worn. I know this for a fact.
Completely agree. Welding gloves are very cheap. Overalls(coveralls) are a little more costly, but money well spent, IMHO.
I haven't used a stick welder in over a year. I usually just use my everlast mig welder for everything but I should practice stick welding every now and then. Gloves are cheap and in a pinch a Jean jacket made of cotton can cover bare skin and help prevent against burns. Safety is often undervalued until someone gets hurt.
no e' l'abito che fa' il monaco
Hi Chris,.... Stephan from South Africa. I've enjoyed watching your video especially the hummers in your comments and your 140 year old welder.....lol. I`ve also taught my self welding and end up by building from small to large broadcasting towers today and any kind of welding you can think of. Pleas don't stop, as you have the personality and courage to do so. If ever possible try and get your self a small Co2 welder, you will be surprise to se what you will be capable of with the experience you already accumulated. All the best and thumbs up. Keep the hummer.
Next level. A tradesman welder would never think to cut an electrode in half. It is however exactly what I need to do for work like this. Thanks.
your a legend, this is spot on the type of welds im planing on doing, building a headboard for my ute tray. keep at it.
Ive just ordered my first stick welder. If my welds are half as good as yours ill be over the moon. Planning on building a workbench for my basement
Thanks for the tips. I will be sure to remember these the next time I stick weld with my powerarc.
This might be the answer I was looking for. I'll try this today and get back to you. I might buy some thinner rods too.
Just what i was looking for, I think Mustie 1 was using this technique with a mig on car welding, but i am glad to see it can be done on square thin tubing without turning it into Swiss cheese.keep up the good work.
Hi Chris. This info is brilliant. I tried it this weekend and after 3 practice tee joints on 1.6mm wall tube I can do a reasonable weld with no blow-thrus. Also tried 1.6mm rods but found the 2.5mm ones (E6013) much easier to use and strike. The stick welder I borrowed is just a small $80 transformer type with a switch selector for 3.25mm or 2.5mm electrodes. Thanks again mate.
Cheers mate! This video helped me out with welding an old trampoline into furniture for my mates bar 🤟
thanks a lot chris for a such informative video, I had to learn this the hard way also, through many penetrated cheap thin tubes, but i think i got a better image of how to get even better/stronger welds now,thanks to you ^^
Thanks Chris for a useful video: it confirmed some points I had worked out by myself. I just wish I had your steady hand. Cheers mate!
Most authentic bloke on RUclips, it was like watching me weld.
I've always had trouble stick welding thin metal. I will try using your advice with my everlast welder.
Chris - great information that I can really use. Thanks.
Was thinking about looking for a video on stick welding thin tubing. Got a cup of coffee and started up RUclips. I didn't have to search for anything at all. Your video was the third one from the top! By the way, I'm not an expert welder but I thought your welds were just fine for what you are using them for. More importantly to me is that I have more confidence about welding desk frames with a stick welder after watching your video. I was starting to wonder how well that was going to go. Thanks for the video and the technique
Nice shop and welding tip!
Nice job, I'm new to welding and I appreciate anything I could learn.
You can always ground the vice. Wicked straight to the point and no waffle. Top vid mate.
I just came to the comments for the heat. Great video - learned a new technique. Thanks!
Thanks for putting this video up. I am making rocket stoves for the island of Tanna in Vanuatu. Had a few issues with blowing holes in the lpg gas bottles, but discovered your method by the suck-and-see technique. Wished I’d found this video before l started doing my builds... would of made for a lot less frustration....
thank you sooooooo much this has been a life saver great help been looking for ages for help on burn throughs thanks again please post more vids
Nice video. Thanks for sharing. I am trying to weld some square tube steel and this will help quite a bit. Thanks again.
Looking to get into welding myself, those look like good welds, thanks for sharing.
Great video.. I have watched plenty of videos on the subject and none of them actually helped, your video was very helpfull
Exactly whats i have been looking for..kinda frustrated with burning a hole on my weld. Cant wait to give this start stop technique a try
I was lmao when u were describing you're welder! I have a similar stone aged one too and just started welding, thanx for these tips man! You described exactly what I was seeking ! Thank u man!!! Nice weld btw 👍👍👍
Spot on video Chris. Loads of advice I can take you up on. Cheers.
Thank you for that ..,. I been burning holes in my project ..... hopefully I can do a better job now !
I to am self taught, however I spent 40years x raying and sentencing welds. You will get better and what I see is great work on such thin steel. Slag removal is always difficult on internal corners and your welds look very strong. No doubt you will burn through and your nest skill is being able to fix it ! Can be done as I’ve done lots of stuff this thin but my welder is an inverter model allowing much lower current. For beginners always fire up the rod on scrape right next to your job, it will always start and nothing worse than a difficult start on a real and important thin walled job. You will get better but are doing real well. I’m a self taught oxy welder and on thin material it’s a cinch you tube will give you the basics.
good video.Had built a lot of safety gates with similar thickness of tubing and aways ended up blowing holes.Will surely try your technique next time.
Thanks man it is great to hear other guys are having to same issues I do. I cannot cut straight to save myself
I have had similar experiences blowing holes. A lot of trial and error, turning the ampage down, getting the electrode hot and short bursts work for me too. I'm not a professional, I get by and my welds hold up. Thanks for the tips.
Those are beautiful welds. If only mine were like those. Oh, well, perhaps in time with more practice. Congratulations.
Thanks mate! I'll definitely try your technique next time! I keep burning so many holes in to thin metal, I keep wonder if I bought a stick welder or a plasma cutter!
LMAO
I just loved the true ( I witnessed it ) time a welding student at the tech school I attended walked up to a small group of us standing around a project being welded up. He looked the welding beads over and made the comment that even a blind man could run a better bead than that. The beads were decent and nobody had really thought different. The instructor who had done the actual welds was among our group. He told the newbi the beads were to specs and what did he think was wrong with them.
The newbi student, realizing he had stepped into a cow pie, sputtered a little bit and quickly drifted off to a distant part of the welding lab area. After a week he had apparently drifted off to Norway because I never saw him again. Best to hold you tongue if your going to be critical.....just in case that subject grades your Certification Test !! Ha Ha ...but very true.
Nice job. Thanks for the video. Warming the tip on some scrap makes good sense.
You’ve encouraged me to try stick welding. I’d also like to try welding hollow section to make a workbench. Thanks!
Thanks for sharing. I’m a newbie and can use every tip I can get.
Awesome job. Glad I stumbled on to your video.
cool video , just got 80 amp arc welder , never welded but theres a first time for everything , thanks for making video need all the advice i can get lol
That is pretty good results for welding thin metal with a stick welder. I usually use my everlast mig welder for thin material to avoid blowing holes.
Why is everyone telling him to wear gloves, he's got a mask and I'm sure he has gloves on the bench or in the boot or somewhere. Good on ya mate. Geez my dad was bloody good. Hardly ever made holes unlike me. " Generate less heat son, stay very close to keep the arc small and move quick". I still made a lot of bloody holes. Ahhh gee love ya dad
I say a job well done. Thanks for taking the time to help others.
And remember, those that criticize another’s efforts and accomplishments have mental issues and should be quickly ignored.
Fair welds and demo only comment would be try continuous runs once started with gentle sweeps side to side to create your fillet. When butting an end to a tube side weld more on to the tubes rolled corner so as not to burn through the cut end, with a continuous flowing run the gap will fill with anode metal melting into the tube end with a nice fillet.
It's good that you have practiced and put out this lovely simple approach well done.
Thank you from a complete novice - your demo was easy to follow and your presentation style isn't intimidating.
I used this method with flux core wire; somehow I didn't think about it when welded with 1/16" 6013 electrode, I was rather trying to find best amperage and speed to weld continuously. Yes thin tubing is most difficult to weld well and I started learning on thin stuff. When switched to 1/4" material it was easy. I wonder if using 6011 electrode would eliminate inclusions since this electrode can be used with whip and pause
Great Video. Thanks for sharing. Please more thin metal stick welding Videos !!
Good job mate. Im a 50yo boily & those welds will be plenty good for diy projects.if they needed to be load bearing you'd just use something thicker. That shs would bend before your welds would give.if you plan on doing a lot more in the future I'd suggest investing in a cheap little mig welder. Much easier on the light stuff. Good vid
Cheers Rod... NSW
some great comments on this post., I have enjoyed reading them. It just goes to show that most home handymen know how difficult some of this stuff can be and appreciate the sharing of tips and knowledge
Your video was quite useful for me. Greetings from Guatemala!
great video! thank you for taking the time.
Good video, I will give it a try. Couple of pointers, if you hold the electrode holder with both hands and brace your arm you can have more control on the rod
love how it makes the jaws sound when he welds
That old welder is super cool!
Very good technique. Definitely trying it
Nice one good buddy - I'm new at welding and have burnt holes - going to give it a go now after watching a pro in action - Thanks
Superb video. I live on an island where they make you rent tanks per month for welding gas. As such, it's not practical. Stick welding is much more economical. This video is exactly what I was looking for. Gates, security bars etc.
I'm normally a wood turner and delve into welding at my peril. I am repairing part of a gazebo for a neighbour and it's VERY thin steel. So far I have a couple of holes at one end, but I will be trying your method toot-sweet, as the French say? Ta foor showing it!!
1/16th inch wall mate....good job....i'd be afraid to stick weld that myself. I'm a master at burning through all thicknesses of material. As kids we used to use a tiny Lincoln stick welder my friends dad had in their garage to "alter" bicycle frames to various shapes and such. Lots of fun on the thin bike frames.
Great demo and information. Thank You!