I have a 1/4 inch gusset i want to burn in to strengthen my d30 bushing mount.



So I have a 120hd lincoln welder good up to 1/4 inch metal. I am using flux (havent set up for gas yet) As you can tell the mount is pretty thin, sheetmetal. I know I have to weld in small sections and let it cool so I dont warp the mount, but question is where should I start to dial in heat and speed? I'm assuming if I turn it up for 1/4 inch steel I'll burn right through. I'll practice on test pieces, just want to get an idea if I should set it up closer to weld thicker piece or thinner metal.

 

You’re going to want to set up for welding the thicker material, and pay close attention to keep from blowing through the thinner material.

When I joint two different thickness metals like that I focus most of the time on the thick material, which quick circles/stitches between the two.

 

Awesome thank you. I'm a pretty novice welder but I figure as long as I dont blow through a bunch, it's not a place I need to look good with nice welds. So to be sure I'm going to drag small circles/zig zag focusing longer on the thick plate and just having the puddle go into the thinner mount but not holding it there?

 

something like this just focusing on the 1/4 inch gusset

 

Yes, like that. Keep a close eye on the puddle, make your moves to the thinner material brief but effective for good penetration on both sides. It’s not difficult, but it does take some experience to make it come it right.

 

Also don't forget to clean up the cut edge on that gusset. Hard to tell from the pic but it looks like a co2 laser cut edge and that should be similar to a plasma cut edge. The n2 laser stuff I've seen has welded fine without taking anything off the cut edge because it's shiny like the base metal and not all black and nasty like a co2 or plasma cut. If you are attempting this I probably don't have to mention cleaning the axle brackets, but there is that as well. Good luck!

 

I like black xj photo. Fancy circles are mostly not need.

Watch the puddle burn it the thick metal with side to side motion mainly to bump puddle over to thin material.

When in doubt burn straight and true leave the fancy foot work for others to talk about..