Welding Sheet Metal

TIP: we highly recommend the #0.5 optional tip especially for 18 to 20 gauge sheet metal

If you have little or no gap, you can fuse weld.

Or you can easily fill up to 1/8" gap - but the prefered method is to fuse weld.

Nice flat weld bead - not a lot of grinding

100% penetration

very little warpage or distortion

General

• The maximum thickness of steel you should attempt is 1/2" - Thicker metals will require preheating.

• #00 for 26 to 28 ga.
• #0 for 24 to 20 ga
• #0.5 for 18 to 20ga
• #1 for 16 to 1/8"
• #2 for 1/8" and thicker
• #2.5 tip may be helpfull on 3/8" and thicker

• Use 4 to 4 1/2 psi on both gases
• If a 50' hose is used, increase your pressure 1 to 2 psi (see setting up the torch)

• Use a neutral or just off feather
• See setting up torch

• No flux required or recommended for welding steel.

Rod material

• Rod should be selected according to purpose. (Generally TIG)
• Auto body or sheet metal: softer rods such as RG-45 / RG-60 will hammer and dolly easier
• If strength is of a concern we recommend - ER70S-2
• Rusty MIG wire may be used
• Coat hangers may be used - but not recommended.
• Shear small strips of excess material and use as a welding rod OK
• for larger rods - eletrodes may be used (knock off flux)

When sizing your rod

• 1/16" for 18 and 20 ga.
• 3/32" for 16 ga. to 1/8"
• 1/8" for 1/8" to 1/4"
• 5/32" for over 1/4"

• When welding sheet metal - heat material until puddle flows readily - this torch will not blow the weld puddle out as others do.
• Move torch in slow small increments - and do not weave or oscillate the torch.
• Do not remove flame abruptly as this may crystallize the weld.