Still learning here with a low dollar flux core welder...I was trying to put a small patch in today on my Regal floor...apx 3x6 or so.. Was thinking to my self that there had to be a better way to cut my new patch out nice and clean..I had a pair of snips, and while they cut easy enough , it was hard to not distort the metal... I have a dremel and air cut off wheels, but I am wondering is there a better way to go..the cutoff wheels and air chisel work nice for opening existing stuff up,you know things that are rigid and structual but I am thinking more so for the new flat stock.. Do I just need to suck it up and stick with the cutoff wheels? Also trimming things up to fit...I find I am either using the bench grinder, file or hand grinder to trim and help shape things after a rough cut, you know trying to get that nice fit without a huge gap... Any tips on going about this in a quicker way ? I mean it works but man it seems like the long road.. Just kinda wondering if anyone had some pointers or would share some tricks they have found to help them out.. Thanks
Easiest/fastest way to cut metal out is a plasma cutter. Other than that a disk grinder with a thin wheel (use welders leather gloves) and use the guard, don't take it off. And be carefull. If you have an air compressor (a must have) the use of a few die grinders (one long, one short) with an arbor for 3" cut-off wheels works well. Try using the .030" thick disks made for stainless steel (a huge difference from using thicker disks). Also when you mark the metal patch being made use the .030" disks to cut the metal. Of course wearing a mask is mandatory as well as a clean shave, all the disk's fibers float in the air. If in a garage air/blow it out afterward. Ray
Easiest way to cut a new patch from sheet metal....use air shears...got mine from Harbor Freight, pistol grip style, and it works great.
Quickest easiest way is a plasma cutter, if you can afford it. It will save you TONS of time. Other than that, you could try making templates out of thin cardboard first, get them to fit perfect, and transfer it to the sheet metal. That way your initial cuts will require less trimming.:TU:
Hi Ray, for my first wheels I tried these 3/64(apx .047") alum/oxide 60 grit discs from HF...I will try some of the skinnier ones.. Need to investigate into protecting the lungs, man it gets nasty.. I'll be making a trip there soon, I will try those , going to pick up the flange/punch tool as well...and order up the Cleco stuff Thats a good idea with the templates...Plasma cutters look cool, but the cost holds that one back... Still playin out there today..strung up a new spool, stuck some .030"flux core in there as opposed to the original 5yr old .035" wire..seems like I got the bacon sizzling a little better, wonder if the new wire made a change or just the size.. just sounds different , not really welding any better or worse, just a little more speed on the feed..
Chris if you can afford to get the gas kit for the mig and drop down to .023 wire. You should be happy with your outcome. The flux core is a lot of smoke and can be quite nasty if in a small garage.
As already mentioned: Thin cardboard for templates. Cereal boxes work great. If you cut the template too small, add to the edges with masking tape. Cutting.... I never used a plasma cutter. Do they leave a nice straight edge? I have used air chisels and HF air shears with good results. But I like the thin cutoff wheels on a electric 4-1/2 angle grinder for most jobs. Even a jig saw works decent. Mark everything carefully and make precise cuts. I've been eyeing the air mini saws, they're still around $80. Welding.... I rarely weld a full bead non stop....it'll burn thru. I do little stitch welds, maybe a half-second at a time, and give it a sec in between to cool down.
I actually have a regulator, just need to get a bottle ..I am doing most of my work outside..I was to understand that maybe the gas would get blown away with even a lite breeze? It seems as though I sit pretty close to the work with the nozzle, so maybe it would help? I am going to give the HF shears a shot. As for welding, my machine has the fixed settings..havnt figured if I am too hot just yet or I am just working with rusty sheetmetal..some sections weld fine, others are blowing through..I think (hoping its not my technique) that its the old comprimised sheetmetal..Next time I pull it out I will try the one and only lower range..I keep coming back to the setting I am at though..
Chris let me know where in Southeastern Mass you are. I have family all through there. I may be able to have someone show you some tips/techniques. Let me know.
As George said the HF Shears are nice. You might want to pick up a nibbler too. I generally buy the fiber reinforced cut off wheels for the Dremel and take your time. They will last awhile if you keep the RPM down. Also since it will remove a ver clean piece it makes tempating the piece onto a piece of cardboard a breeze. Shears/Nibbler/Chisel/Cut off wheels distort the metal soem but the Dremel will remove the exact piece you need to remake. Like anything... Haste makes Waste. Jon
Sorry a little late, missed ,no email notifications yet..I do use the Dremel,even opted to try the new quick conect shaft/discs. Have been using that mostly tillI just picked up the 3" air cut ff tool. I did pick up the shears, havnt cracked the box open yet.. I did try flanger , works pretty good.. Still pulling apart old sheetmetal for now, just about ready to start the repairs.
