The At Home Welder » How To Weld

How To Fix Your Welding Screw Ups – Part 2

HomeWelder — Thu, 08 Jul 2010 22:20:56 +0000

In a previous video, I showed you an embarrassing mistake that I made while welding up a custom iron railing. The mistake wasn’t noticeable until I got the whole iron railing out on site and started the installation.

Thankfully I was able to fix everything on site. Since I had my iPhone with me, I decided to take a quick video of what happened and how I was able to fix it. The problem is, this was a solo install and I was the only one there. It’s impossible to weld and hold video phone at the same time.

Many of you emailed and commented saying that you really wanted to see the actual welding process in action. So today I went into the shop and filmed a reenactment of what happened and the exact welding techniques that I used.

Part 2

This video’s a little long but I show in “real time” exactly how I fixed the problem.

Click here to view the embedded video.

I hope that answered everyones questions about how I fixed the iron railing I was installing.

If you have any other questions or comments, please feel free to leave them in the comment box below.

PS> For everyone that signed up for the Iron Railing 101 Early Bird list, don’t forget to look for your email coming tomorrow (Friday) afternoon. Since you guys have been so supportive, I’m letting you have first crack at the course. I’m only doing the early bird thing until Monday though. After that you’ll have to pay top dollar and those special bonuses will be gone. It should be there around noon tomorrow.

How To Fix Your Welding Screw Ups Without Looking Like Fool In Front Of Your Customer

HomeWelder — Mon, 28 Jun 2010 16:26:39 +0000

This past weekend I was installing a beautiful railing for client that I had worked with before. I went through all the normal motions of measuring and finding all the perfect angles and went back to the shop to create some new iron railing goodness.

Everything went smoothly in the shop and I finished up all the fab work in a pretty short amount of time. The problem showed it’s head almost immediately when I began to set up the railing to bolt down to the deck.

My BIG Screw Up

In this quick video you’ll learn how to quickly fix a welding mistake, that can happen to anyone, without looking like a total idiot in front of your customers.

Click here to view the embedded video.

No matter how experienced of a welder you are, these types of mistakes will occasionally happen. Chances are I probably just accidentally bumped something and it threw everything off.

How Do You Handle Mistakes?

What welding mistakes have you made in the past and how did you deal with them? Let me know in the comments below.

Don’t Make These Mistakes With Your Iron Railings

HomeWelder — Sun, 11 Apr 2010 02:59:12 +0000

This is the first in a series of posts that are going to be taking you deep inside the formula I use to create killer custom railings. This is definitely some good stuff for you know. Welding up iron railings is what makes up around 90% my welding business.

Click here to view the embedded video.

Stay tuned because I’ll be posting some more here soon.

55-gallon drum smoker

HomeWelder — Mon, 04 Jan 2010 21:37:20 +0000

I came across this today and well… It brought a tear to my eye.

Not really, but this really is the best step-by-step DIY guide to building your own smoker I’ve ever seen. The end result is simple and beautiful -not like most mutated gas tank BBQ abominations I see on the internet – and any one could do this from home with very minimal tools or skill.

I couldn’t find his name but I think it’s Joel.

So Joel, if that’s your name, the At Home Welder is officially giving you props. NICE WORK!

The following is the DIY Smoker post from Joel’s (sorry if that’s not your name) site, Design & Make. Enjoy

55-Gallon Drum Smoker

This past fall I took an evening welding class at a local technical school and got very excited about making things out of metal. I already had an old stick welder that I didn’t really know how to use, and I ended up buying a MIG welder–the Hobart Handler 140 from Northern. After making lots of small assemblages out of scrap metal I managed to build a stool and a couple of plant stands, but I had bigger plans.

There’s something special about creating useful objects. A smoker is a nice combination of supremely useful (preparing sustenance) and slightly frivolous (do you need a smoked pork butt to survive?). There are certainly faster and more efficient ways to cook food, but damn smoked meat is good.

I looked around at commercial smokers and custom hacks and talked to a few connoisseurs, and decided the Weber Smoky Mountain was a good design to start from. It’s simple and effective, and in the end it mostly convinced me that the design need not be complex.

Something appealed to me about using the iconic 55-gallon drum as a building block, so I went out and bought a couple from the local scrap yard. One of them even got immediate use as a beer barrel at Crushtoberfest!

A little sketching on different configurations, and I decided a ‘T’ shape would be simple, stable, and functional, and provide plenty of opportunity to practice the MIG on some thin sheet metal. I laid it out in CAD, which made it easy to generate the intersecting curve between the two barrels.

I printed the curve at full scale and wrapped it onto the barrel, traced the curve, then cut the barrel with a jig saw. The first dry fit was amazingly close (way to go, CAD!) but there was still a lot of grinding here and there to accommodate the ribs in the barrels.

I measured and marked the door openings on the barrels and cut them out with the jig saw.

The next step was grinding the paint off. The last thing I wanted was burning paint fumes getting into the food, so every bit of paint needed to go. If I were to do this again I would find another way… sand blasting, chemicals, burning it off, etc… anything but taking it off little by little with an angle grinder. I’ll admit the Gator brand paint & rust remover discs I found at Lowes were very effective (if a bit pricey at 9 bucks a piece). But my shop is now coated with a thin layer of green paint dust, much of which ended up in my nose and likely my lungs.

On the first day of grinding I wore a respirator and glasses but nothing else. After washing my hair three times in a row to get the paint dust out I learned to don more protection. For the insides of the barrels I also used an LED headlamp.

As the barrels were made of surprisingly thin metal (20 gauge) the door openings needed to be reinforced with some angle and rolled sheet metal strips, which were plug welded from the outside and tacked from the inside.

The doors also needed reinforcement, in the form of sheet metal ribs tacked onto the undersides.

I welded small pads onto the barrels and doors for the stainless steel hinges. These pads were ground flat then drilled and tapped.

After grinding the rest of the paint off I welded the two barrels together. This was a challenge, since the metal was so thin and the fit was far from perfect. To prevent burn-through and warpage I used a “stitching” technique where you put a quick tack weld across the joint, wait a second or less and put another tack next to it, continuing like that for about an inch at a time. Apparently this puts less heat to the metal than a continuous bead, but the end result looks very similar. With a little practice I was even able to bridge relatively large gaps between the barrels with short, controlled beads that build on each other, kind of like ants crossing a stream.

I shopped around looking for off-the-shelf replacement grates that would work but none of them were big enough for this guy. So I bought about 80 feet of 1/4″ diameter 304 stainless rod (from onlinemetals.com) and cut it to length on the abrasive chop saw. I scored a piece of 1x pine on the table saw at the proper spacing to use as a jig, and clamped the rods down. The MIG would have been perfect for welding the grates, but I would have needed to buy stainless wire and a separate tank of tri-mix gas (65% argon, 33% helium and 2% CO2). The stainless itself was already pushing my budget, so I bought a handful of stainless welding rods and used the arc welder.

Next I drilled holes for the dampers– two sets of three holes at the top and two sets of four holes the bottom. The top ones were made like typical grill dampers with a round rotating plate. The bottom ones needed to be on a curved surface, so they slide along the surface rather than rotating.

In both cases the moving damper is retained by screws, so I drilled holes and tacked some steel nuts behind them.

I then drilled a series of holes to allow the smoke and heat into the top barrel. My step drill bit did an amazing job, but the cordless drill still went through two fully charged batteries getting the job done.

Next I tacked on some small support tabs for the grates and six small sections of square tube as feet.

After a thorough deburring, wire-brushing and degreasing with alcohol, I set about applying a high-temperature grill paint. There are several available but Rustoleum High Heat Brush On was a) available at Lowes and b) didn’t require curing at a high temperature like most of the products I found online. Unfortunately it only comes in black, which is actually slightly brownish. They recommend only applying one coat, which I agree with after trying to touch up a few spots after drying, resulting in some weird gloss differences. I then tried the spray can version of the same paint, but found it to be flat finish (vs. the brush-on which is satin). The lesson here is get it right with the first coat because you really can’t go back and hit it again.

While the paint was drying (24 hrs… it’s oil-based) I fabricated some handles out of a 1″ maple dowel. I don’t have a wood lathe but the metal lathe did the job. A few coats of Polycrylic and they’re ready to assemble.

The smoker can be used in one of two different ways– with charcoal in an expanded metal basket or with wood on a traditional fireplace grate. I suppose I could retrofit some gas burners or even electric heating elements, but that’s a project for another day.

And last, final assembly. I bought a 3″ smoker/grill thermometer online, and used some nickel-plated chain for the lid stays. I also fabricated a sheet metal “drip tray” to cover the holes under the food and deflect some of the heat.

I figured my brother-in-law Pete would make much better use of this than me, so we gave it to him for Christmas. Here he is opening it…

WT 09 | Cutting Torch Basics And The Welders Best Friend

HomeWelder — Thu, 03 Dec 2009 16:40:52 +0000

In this episode you will learn how to get started with your oxygen/acetylene cutting torch. Surprisingly, most people have no clue how to get their torches started correctly or even how cut with them.

There’s nothing more embarrassing than everyone hearing that loud *POP* over and over because you can’t keep your torch lit.

As a welder, do you know who your best friend is?

Listen and learn who your best should be and how to find them.

Episode Length 19:47

Subscribe in iTunes

Download this episode to keep

TAKE ACTION

To take advantage of my mistake that I talked about in this episode – Go Here

Let me know what you think about think about this episode. Leave your comment in the comments section or in the comment box for this post.

Until Next Time – Keep The Sparks Fly’n

PS> This is the only chance you’ll have to get the course this low. It will never be offered at this price again. There is only 2 days left. ACT NOW to save big.

WT 08 | Tips And Tricks For Welding Galvanized Metals

HomeWelder — Thu, 19 Nov 2009 17:01:31 +0000

In the episode you will learn some of the best tricks for welding galvanized metals. You will also learn how to avoid and treat one of the greatest fears of welding steel that’s been galvanized, Metal Fume Fever.

We also answer a great question about keeping finials straight when welding custom fencing

and…

an At Home Welder webinar?

Episode Length – 17:00

To Subscribe and Rate this podcast in iTunes >>CLICK HERE<<

COMMENTS & QUESTIONS

Have you ever experienced metal fume fever? What was your remedy and what was the project?

Let us know by leaving your answers in the comment box HERE

The 7 Welding Resources You Can’t Live Without

HomeWelder — Fri, 13 Nov 2009 21:52:25 +0000

We all have our little lists of our favorite resources. The places that we keep returning to time and time again because they always havewhat we need and they can always answer our questions.

Well this list is no different. I compiled a list of 7 of the greatest resources you can have as an at home welder. I use almost all of these resources every month and they’ve all saved me loads of time, money, stress.

So here they are…

They 7 Resources You Can’t Live Without

King Architectural Metals – King is the place to get everything you need. From raw steel and hardware to ornamental elements and paints. King is my number one source for anything I can’t get locally.

Metal Supermarkets - This is a great place to get the exact amount of steel that you need for each job. Metal Supermarkets will sell and deliver steel by the foot and only charge you for what you need. Most steel suppliers will gladly sell you a few feet but they’ll make you pay for the whole piece.

McNichols - If you’re looking for hard to find mesh or grating materials, this is the place to call. Steel, aluminum, stainless steel, McNichols covers it all. They cost a little more than others, but they have a lot of stuff that you cant find anywhere else. They’ll deliver anywhere too.

OSHA Railing Codes – keep in mind that these are written in OSHA talk, which means it reads weird at times. It’s still pretty clear as to what is required. Start in section (d) for stairway railing and guards.

Harbor Freight – A great place to find good tools of all kinds really really cheap.

Northern Tool - Northern has been around for forever and their tools are as good as their reputation. I’ve used Northern brand tools like grinders, chop saws, air tools. They’re half the price of the big names and last just as long.

NOMMA – This is an incredible resource for all welders. They stay up on all current code changes, welding technology, business models, metal practices and just about anything you can think of that deals with working with metal. It does require a yearly membership that isn’t cheap, but when you can afford it, I strongly recommend that you join. They produce the Fabricator Magazine.

If you have any great resources on your list, please share them. It’s always great to hear about what’s working for others, besides, we can all benefit from each others recommended resources.

COMMENTS & QUESTIONS

There’s a new way to connect with me. Yep, I’ve gone fancy and The At Home Welder now has a phone number. True, it’s a little cheesy, but when I saw it was available I knew I had to get it.

Now you can call…

860-HOT-WELD

And of course, you can leave any comments and questions in the comments box or look up HomeWelder on Twitter and Skype.

Mig Welding 101 | Wrought Iron Railings (sneak peak)

HomeWelder — Thu, 12 Nov 2009 16:21:30 +0000

Click here to view the embedded video.

WT 07 | Choosing The Right Welding Gas

HomeWelder — Thu, 05 Nov 2009 22:08:21 +0000

In this episode we will cover how to choose the right welding gases and when is the best time to use them.

It is very easy to just use what you have and think that you’re safe. But in many cases you have to use specific gases for different materials. If you use the wrong ones, your welds won’t be worth a dime.

I also answer a great finishing question on how to get that rustic look without actually letting your metal rust.

Rust = Death to metal

And the 1st ever At Home Welder contest is born with a grand prize worth over $500.

Episode Length – 17:09

Listen in iTunes

The Contest

Send your name ideas to weldingtips@theathomewelder.com

I’m going to choose the best one and give the winner the entire railings course for free. That’s well over $500 worth of material. Even if I decide not to use it, you still get the course.

Questions & Comments

As always, if you have any questions or comments, leave them in the comment box or email them directly to me at weldingtips@theathomewelder.com

WT 06 | How To Avoid Blowing Holes In Your Metal When Welding

HomeWelder — Fri, 23 Oct 2009 16:34:45 +0000

In this episode you will learn some excellent techniques on how to control your welding heat to avoid nasty blowthroughs and how to repair them if they do happen.

In the Q&A session, an AHW community member gets an answer to one of the most frequently asked questions by beginning welders.

Episode Length – 17:20

Subscribe in iTunes

TAKE ACTION

Practice the pull away technique described in the show. This is the best technique to control your heat without having to stop welding. If you can master this technique, you’ll greatly speed up welding which will allow you to move on to something else.

QUESTIONS?

Leave your comments and questions in the comment box. I love hearing what you have to say and they types of projects that you’re working on.

AHW 05 | How To Avoid Heat Distortion

HomeWelder — Thu, 15 Oct 2009 02:12:38 +0000

In this episode you will learn the best way to avoid heat distortion when welding sheet metal. It’s easier than you think to master great welds when working with sheet metal.

I answer a great question from an AHW community member about how to find the perfect materials and I unleash a huge announcement about the future of The At Home Welder Podcast.

Episode Length 17:21

COMMENTS & QUESTIONS

Do you have a question that you want answered on the show?

Leave them in the comment box, Shoot Me A Bird, or email

The Question That Will Change Everything

HomeWelder — Thu, 03 Sep 2009 02:59:13 +0000

IN THIS POST

I ask you the question that could change The At Home Welder forever.

Click here to view the embedded video.

TAKE ACTION

Send me your top 5 picks.

Here’s how:

Email Me
Twitter
Facebook
Comment Box For This Post

Any of these will work just fine.

I can’t wait to see your answers and how they’re going to shape the future of The AHW.

AHW 01 | The 5 Fears Of Starting Your Ornamental Welding Empire

HomeWelder — Thu, 23 Jul 2009 00:30:37 +0000

In This Episode I officially introduce myself and give you a brief (maybe not brief enough) summary of who I am, why I am here, and what I am going to do to grow your abilities and your business.

I also answer the 5 main questions and fears of starting your own ornamental welding business from home and I give you 2 of the best resources you could have if your just starting out.

Length 26:37

Listen in iTunes

That’s right, it’s finally here.

For those of you who have been following me on Twitter, you know that I’ve been teasing you with the thought of an AHW podcast for while now. TADA!

Yes, it’s a little rough around the edges, but hey, I’m new at this.

MENTIONED RESOURCES

Home Depot Rental Store Locator

As always, if you have any comments or questions please leave them in the comments box for this post.

Welding Safety Tips Every At Home Welder Needs To Know

HomeWelder — Sat, 11 Jul 2009 18:46:57 +0000

“It’s the simple things that’ll always get you.”

That’s what one of my mentors said one time when he was giving me one of his off-the-wall lessons about welding safety. His lessons were usually strange and most of the time I think he just liked hearing himself talk, but what he said really stuck with me.

It’s easy for us to remember the big things like,

Keep your hands away from the saw when it’s on
Don’t smoke next the gas tanks
Don’t weld in room full of TNT

I think you get the point. However, it easy to get comfortable in your abilities and forget about the little safety measures that come into play more often then say, welding in a room full of dynamite.

IN THIS POST

In this quick video I go over those simple safety tips that you need to know and remember every time your having fun with a project.

Click here to view the embedded video.

TAKE ACTION

Think about the last project you worked on or take a look what your creating now. Are you ignoring the little things and just focusing on the big ones? Make yourself a safety checklist ( a reminder really ) and put it on the wall in a spot where you’ll see it while your working. It won’t take long before their engraved in your brain and they’ll become second nature.

QUESTIONS OR COMMENTS?

If you have something to say, let me know by leaving your comments and questions in the comment box.

Basic Mig Welder Settings: Finding The Perfect Setting

HomeWelder — Wed, 13 May 2009 23:26:59 +0000

Welcome to the first official post of The At Home Welder.

In this post, we’re going to cover some of the basics on correct mig settings. The settings you use when welding will play a major role in the strength and quality of your welds and overall project. Although most welders will come with a chart of recommended settings for different metal thicknesses, it’s important to play around with this on your own.

Click here to view the embedded video.

TAKE ACTON!

Grab some scrap metal and start playing around with your welders settings. Find which settings work best for your style and different materials.

If you feel like you have any questions or comments about anything, please let me know by clicking the comment link under the title and leaving them in the reply box.