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need some tips ( welding 1" to 3/16")

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  • need some tips ( welding 1" to 3/16")

    whats up guys, didnt get my HH210 yet but its should be here tomorrow and of course im going to do plenty of practicing to get used to this machine before i start a project...

    but im going to be welding a 1" thick shackle mount onto 3/16" rect. box using flux core (dont have money for gas yet and ive been using flux since ive been welding)...

    heres a pic:


    the shackle mounts is going to go through the boxed steel so i can weld it on both sides (for strength)

    i just need some tips on welding 1" to 3/16" ive never done that large of a size difference before...

    jason

  • #2
    I would think that the 210 would have plenty of get-go unless the 1" takes the heat away to fast. One of the pro's will have to offer input on that one. But as long as it has enough power, you would most likely concentrate your heat on the 1" and wash into the 3/16 and then back to the 1". Not completely sure on your app...... it looks like you are working on a frame of some sort. Oh he!! I bet this is your front bumper isn't it. If so, I would think you need to use maybe a 1/4" plate a couple inches larger then the shackle to spread some of the load across the 3/16. You can still punch it thru, and have another 1/4" plate on the back side. Again this is my opinion, and I am not a pro by any means.
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    • #3
      If the shackle mount is extra large you might want to preheat it to about 250 degrees, otherwise just put a 3/16 fillet around it on both sides and you will be good to go.
      Flash me! I'm a welder.

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      • #4
        Originally posted by Bob the Welder View Post
        just put a 3/16 fillet around it on both sides and you will be good to go.
        Absolutely correct, and this is a point a lot of people seem to miss - even if you somehow achieved 100% penetration on the 1", the joint will never be stronger than the 3/16".

        Overwelding a joint doesn't make it stronger, and in some cases is actually a detriment.
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        • #5
          can someone explain this "fillet" thing you guys are talking about?

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          • #6
            nevermind i gues its just the type of weld id be doing in that situation, but yes on all 4 sides im going to and on the back all 4 sides as well... by 3/16, do you mean 3/16" span bead on both surfaces from the seam?

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            • #7
              I hope you only chose to go to 1" for looks or because it was on hand. otherwise 1/2" should hold until your 3/16 bumper gives. (given: I assume it's a bumper, granted: I don't know the cross sectional strength of your unknown tubing size)

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              • #8
                Originally posted by trial&error View Post
                I hope you only chose to go to 1" for looks or because it was on hand. otherwise 1/2" should hold until your 3/16 bumper gives. (given: I assume it's a bumper, granted: I don't know the cross sectional strength of your unknown tubing size)
                im going with 1" because the tabs come premade that thickness...also im thinking of doing the front piece 1/4" instead of 3/16" now





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                • #9
                  no to the 1/4"

                  Hey Jason. What vehicle is this for? How seriously will it be used?
                  I've built many similar pieces and might have an idea I can impart for your project.

                  Here's the rear bumper I built for my work truck:
                  (Still going strong after fifteen years)


                  Mike

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                  • #10
                    Originally posted by old blue View Post
                    Hey Jason. What vehicle is this for? How seriously will it be used?
                    I've built many similar pieces and might have an idea I can impart for your project.

                    Here's the rear bumper I built for my work truck:
                    (Still going strong after fifteen years)


                    its for my 99 Jeep WJ:



                    im open to any and all ideas, also i think im going to go with 3/4" shackle mounts instead of 1"

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                    • #11
                      The 1 inch does offer an advantage, it distributes the load out just a tad more than the 3/4 would. For an off-angle pull that would be more critical.

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                      • #12
                        My vote goes to over cutting your threw plate connection a touch for Complete Joint Penetration then welding at 3/16" or 1/4" weld on both sides, it's got it. For Self Shield I like Hobart Brothers Fabshield 21B. Fabshield Has a 91,000 psi. tensile strength and good bead appearance for Self Shield. Just my $0.02
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                        • #13
                          which wire would you guys recommend .030 or .035?

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                          • #14
                            Of the two .035" would be my choice
                            Esab Multimaster 260 Sweet machine!
                            Thermal Arc Arc Master, Don't use it much just got a heck of a deal on this unit
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                            • #15
                              A better bumper

                              Shhhhsh thats the kind a bumper I need on my truck.... Adding a big light hasn't helped much
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