i grind my sheet metal welds too far Certified welder here, grinding flush is normally how you make a butt weld as strong as possible, but normally doing stitch welds on sheet metal causes a lot of discontinuity (lack of penetration being the main one) so if you grind too far .
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0 · grinding welds on sheet metal
1 · grinding welds in tight corners
2 · grinding down welds sheet metal
3 · grinding down welds on metal
4 · grinding down welds in corners
5 · grinding down welds before starting
6 · grinding down sheet metal
7 · can you grind down welds
What is the best way to transition from THHN wiring in exposed conduit to a wall panel inside a wall? The conduit holds wiring for a 120v circuit and a 240v circuit with power outlets. I was going to use a 4x4 junction box to transition through the back of the box into the wall using using romex behind the wall.
I have been using a 5 inch angle grinder with a 120g flap disc but I don’t feel 100% consistent and am paranoid about taking it down to far or unevenly. 5 inch is potentially too wide and taking metal off the surrounding .
One trick that is most common is listening to the grinder’s pitch. If the pitch is too low then you might need to let go of the pressure a little bit. On the other hand, if the pitch is too high then you should apply more pressure. The perfect . Make sure you're using the right gas flow and correct wire if you're doing mig. Grinding off a large amount of material makes the area hot and then wavy. You should be able . Go slightly past the weld and ease off when you start to dust the surrounding material. Pulling the grinder instead of pushing is also more .
In a certain sense you are right, but you still are NOT allowed to grind a structural weld. If you want a flatter profile there are options. for instance the selection of welding .Certified welder here, grinding flush is normally how you make a butt weld as strong as possible, but normally doing stitch welds on sheet metal causes a lot of discontinuity (lack of penetration being the main one) so if you grind too far . The main issue when working on sheet metal and grinding, etc, we know heat is your enemy, so go slow, bounce around in your work area, resist getting aggressive.
A router is probably the easiest and safest method. As long as you keep the router flat the guide bearing will keep it from digging too far. For grinding down MIG welds on sheetmetal, what is the best thing to use? From what I understand, a 4" grinding wheel creates too much heat, as well as a 4" grinder with . If you over or under weld a joint, making the weld too concave or convex, you can make a weld weaker, and create stress points. There is a reason that grind limits and undercut .The metal is 1mm thick so a normal weld would heat up and warp the panels. So apparently in the automotive industry they use tac welds. You have to spread them out and rest inbetween welds to prevent it heating up too much. Gotta be .
I dont like flapper wheels on sheet metal they seem too soft and form over the weld (which if you are mig welding is harder than the sheet metal) and dig into the surronding area. Try an abrasive disc with a hard backer (like a 2 or 3 in roloc on angle die grinder or 4 inch abrasive wheel in 36 to 80 grit). As far as penetration, you have a good weld proud on the back side, good for planishing. Note the weld seam is still visible. If we overlap the weld dots, it will resolve that so when you weld, planish, grind, and then do sanding after .Took me a long time to actually lay decent beads. If your machine has a setting for wire speed for your size of wire use it. And then look on the spec sheet for the thickness of metal you are welding on. Also galvanized is the worst to weld on. Make sure you grind any paint, coating, and mill scale off when just starting out.
Gaps will kill you as you've learned. Here's the best approach I know. When you are butt welding sheet metal, every weld should be a tack weld. Just keep welding "dots" until you've connected them all. You may want to grind or at least partially grind the welds when they get close together.
Go slightly past the weld and ease off when you start to dust the surrounding material. Pulling the grinder instead of pushing is also more delicate. Even though you're taking off some material around the weld, you will get a smoother result than if you only try to grind exactly on the weld. Hard to describe without showing, but I hope this helps.
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With the limiter/regulator set on 7 for every damn thing my father and I have welded who is a very skilled welder, wire feed set on around 6-7, and adjusting my 2 switches for voltage and current to the variety they offer but sometimes maxed, I've been able to get good welds on sheet metal and thin wall pipe like non-galvanized conduit.
My welding skills are fair, depending on what I'm welding. The thicker the metal, the better my welds. I have to smooth over every weld in sheet metal though. For me, it is always a moving target to have the welds hot enough to penetrate but not too hot where they burn through. In short, I have to grind everything to get it smooth. Grind them down smooth and you might have to make a few more tack welds to get some holes you missed. Keeping the heat down is the key. If you make a continous weld you will warp the sheet metal. I dont use flanges, I cut my patches to fit with a SLIGHT gap between the panels for good penetration with a tack.Sheet metal worker here. We weld galvy every day. It's fine it just sucks because the zinc coating makes a lot of pops and splatter. nd the smoke is nasty just make sure there's good ventilation use fans and try not to breathe it too much. . Also by far the best tip for welding Galvi, use flux core. The flux actually gasses off in the weld .
First Generation Camaro Info and Tech - 1967-1969. Body Shop Just like when I lap weld I start at about 2" apart and then go about putting welds in between the spot welds until I have a solid weld. I wire brush the welds then check for spaces. I think I have a solid weld until I grind the weld and I can see very small holes between some of .
grinding welds on sheet metal
Prepping that metal prior to welding.grinding off the mill scale. . Our sheet metal is clean and for me to have a grinder going all day long Welding 30 different spots on the sheet metal where the 3 inch wells will go it’s pure goddamn insanity. . It’s making your wire yeild smoothly as it travels From A-Z. Makes the weld look nice and .
You'd be better off with a 70/30 mix than using Co2 without a doubt. If you do a lot of sheetmetal welding go with .020 wire and tips. show some pics of the weld before you start grinding and we can be more help. my best guess is your trying to weld too cold. and yes, you cant just run a bead with sheetmetal, its tacked, spaced and tacked again. while your getting .the big question is, what is this for? if this needs to hold weight or be water tight, you'll need certain welds. personally, I'd make the bottom sheet an inch or two larger in every dimension, trim the corners, then bend the excess to 90 degrees. this changes the weld from a corner weld into a lap weld, which is much easier to do on sheet metal.
Grind first though. Recheck with light after any grinding. When its all done, probe around the joint with a pick or slow drill. Because the cracking often percieved as a fault in MIG welds is just where the sheetmetal is too thin .
Fabrication, Tools, Equipment . Once you're set up and ready with your metal clamped into place you can start your tig welding tig welding sheet metal is a lot like tig welding any other kind of metal with only a few changes to technique .Ehh, lots of people weld up custom frames and don't do any fancy heat treatments. It should hold fine, just keep an eye on it. 2 stroke swaps are a common conversion for modern 4 stroke MX frames, and it almost always requires cutting the downtube and welding in a taller Y member to fit the center exit 2t exhaust. Grinding sheetmetal mig welds I used a die grinder with a cut off wheel to knonk the weld down a bit, they provide great cutting and minimal frictionm ie; heat. then you can use a 4" flap wheel, but dont work any one spot to long as the metal will oil can. Its also a good idea to keep a damp rag around to coolthe metal down as you grind.
I am a complete amateur as far as body work. I typically start out with a used/worn disk (mine are 4 1/2") to grind the welds down on sheet metal. . you don't want to get the metal too hot! . (mine are 4 1/2") to grind the welds down on sheet metal. The worn disk has a flat area instead of a new sharp edge to grind with. That will take it . I really like using the carbide burrs from Kodiak in my die grinder Carbide Burr Sets | Double Cut Carbide Burrs | Kodiak Cutting Tools. They cut the weld like butter and I have a lot of control with them. I'll get my welds real close to the sheet metal surface and then switch to a 2'' disc with either 40 grit or 80 grit. I have rarely been able to "jump a gap" when butt welding sheet metal. It can be done,but I have to build up both sides a bit so that the metal is now a little thicker with material. I found that it is crucial to having the sheet metal flush with each other(lap welds) or touching completley when butt welding. Just some thoughts about my experience.
A long weld bead is kind of like a long hot cable, and as it cools, it shrinks and shortens up and puckers and pulls the surrounding sheet metal in with it. The weld bead is stronger and thicker than the surrounding sheet metal, so the sheet metal loses the battle. Oh, by "grind", I mean sand it down. An actual grinder wheel gets the steel too hot.You need more heat and shielding gas. Not trying to be an ass but those welds are bad. You should practice on scrap, cut gaps with a cut off wheel in some sheet metal and practice doing butt welds. Edit: you also need to spend more time getting your metal clean of contaminants and bare before you weld. They all look super dirty.
Whipping vertical down hill when you can, helps control the puddle speed without completely roasting the metal. Or just go downhill fast. Horizontal, aim for the top of the joint and watch the penetration on the toes. This should also be fast. Your welds aren’t the worst by far, just keep practicing on some thin gauge metal if possible. I TIG weld sheetmetal 19guage buttweld hammer and dolly after , needs to be close to perfect fit between sheetmetal edges , MIG weld wire 0.6 or 0.8mm thick , tack weld and then 1-1,5″ spread out , hammer down the weld , if lost aka cool down , grind down and then hammer abit . the thing with hammer the weld is falleting the weld and .
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grinding welds in tight corners
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i grind my sheet metal welds too far|grinding down sheet metal