Q & A details - Any tips for stick welding two different thickness metals?
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Any tips for stick welding two different thickness metals?

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I'd like to reenforce the front frame on my Escort with some nice thick 1/8th in steel, but the frame on the car is probably half that thickness. Are there any tricks or tips from the experienced stick welders out there, on how to properly weld thicker metal to thinner metal?

I would be using a small 220v stick welder up to 100amps with 3/32 rods. I have both 6011 and 6013 rods, and I would probably use the 6011 ones.

It's easy welding on the older vehicles with thick frames... but trying to weld on the thinner frames is something I need to get used to.

Thanks so much!
Update: This is an electronic welder. I can adjust amps between I think 45 and 100 amps. 

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  • 0861788249

    0861788249 2017-02-23 09:07:37

    E6011 and E6013 are both almost obsolete, I can only think of one or two applications where you'd want to use them over something else. If you try to use 6011, you can watch your arc blow right through the thin car frame. (There's a reason they call this stuff "farmer rods") In any case stick welding is not suitable for anything under 1/8". You're going to get burn-through, very inconsistent weld fusion, as well as way too much heat input to the steel. In other words, in order to avoid burning through, you'll have to go way too fast or use too low of voltage to make a consistent weld. Most of the structure in a modern car is made of high-strength steel, so heat input is a major concern. Just because a weld LOOKS good, doesn't mean it IS good. You really want to be MIG welding, it has the lowest heat input, and performs far better on thin stuff. It also makes better welds than E601x series stick electrodes. Get a pro to do this if you must. Secondly, exactly why is it necessary to "reinforce" anything? Remember that cars are designed to buckle and crumple in very specific ways, to absorb energy during a crash and cushion the driver. reinforcing the front or rear end will likely make the car LESS safe in an accident, not more so. The frame of a car is designed to save your life. Why do you want to be putting amateur-quality welds in it? Note: If you're trying to add a roll cage, that's OK, but you would need to know what you're doing. Again, you don't want a roll cage to fall apart due to crappy welds, when your life's on the line... In conclusion, in good conscience I have to advise against this.

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