by Bill Wilson
Welding is a handy skill to have, not just for working on cars and trucks but also for doing general repairs around your home or for friends and neighbors. In this installment we’re going to cover the fundamentals that you need to know to set up a safe, simple and effective welding station with which you can do basic welds.
This article is intended as a high-level introduction to the subject, not as an in-depth tutorial. If you’ve never welded before and you want to pursue this subject further, there are plenty of more advanced learning resources available, from books and videos to classes offered at tech schools and career centers across the country.
What is Welding?
Simply put, welding is a method by which two pieces of metal are joined together by applying extreme heat to both. Done properly, the result is a bond between the two which is incredibly strong and durable. All types of metal can be welded, including iron, steel and aluminum. Even different types of metal can be joined in this way, such as aluminum and steel.
Safety Considerations
Welding has a reputation, largely undeserved, for being a dangerous profession. This is due primarily to the fact that it involves creating the extremely high temperatures needed to melt metal. For example, to melt iron or steel requires temperatures close to 3000 degrees Fahrenheit (app. 1600 degrees Celsius)!
To do this usually involves generating electric arcs or using combustible gasses that are under high pressure and are set aflame with a spark. If caution isn’t exercised when welding, the result can be severe shocks or damage to the lungs from inhaling fumes. In addition, burns to the skin or the eyes can occur if proper safety equipment isn’t worn.
Fortunately, these kinds of hazards can be avoided by following some basic precautions. Here’s a list of equipment that you’ll need before you start welding.
Helmet/Hood
This is an absolute must for any welder. Welding arcs give off intense amounts
of ultraviolet radiation, which can do the same damage to your eyes as staring at the sun for long periods of time. To protect against this you need a hood, also known as a helmet, that covers your eyes, face and neck. Cheaper ones have lenses that you can change out by hand, but nowadays most welders use auto-darkening masks that automatically adjust to give your retinas the necessary amount of shade.
These hoods can be found for as little as fifty bucks or so, and do an excellent job of guarding against vision loss. Amazon.com and northerntools.com both sell them, or you can just visit your local welding shop.
Gloves
These are a necessity for welding. Some seasoned welders get by with cotton or wool ones, but for a beginner there’s real only one choice. Buy a pair of quality cowhide ones that cover your hands and forearms and are insulated. NEVER use gloves made of a synthetic material, as these will invariably melt or catch fire, injuring you seriously.
Apron
Another item you simply cannot afford to do without. Get a quality leather apron. It will protect you from flecks of molten metal that occasionally leap off the work area. If one of those touches exposed skin then you’re going to the hospital.
Hat
Especially important if you have longer hair. Wear cotton, not synthetic. Yes, cotton can catch fire, but in this case it’s acceptable, since the only other alternatives usually available are made of synthetic materials that can melt into your skin. Welding shops have cheap hats that are made especially for this purpose.
Basic Safety Practices
Wind and bright sunlight are your enemies when welding. The sun makes it harder to see the flame from your torch, and wind or fan-blown air will interfere with the gasses and electric arcs needed for a strong weld. Do your welding inside the shop, and be ready to deal with the heat. In the summertime keep plenty of cold water or one of those thirst quenching drinks like Gatorade close at hand. If you find yourself sweating profusely or getting dizzy, STOP and take a break. Heat stroke will kill you quick.
While you don’t want wind or fan-blown air, you do want plenty of ventilation in the area where you’re working. Welding creates noxious fumes that can choke you. Be certain you’re not in a tight or enclosed area.
Make sure the pieces you’re welding together are well supported. Metal supports known as “dead men” are readily available, or you can make your own from threaded rod. The parts you’re working on MUST be in the correct orientation, else you’ll be doing the job a second time, and that’s no fun at all.
It can be tempting to just lay the pieces out on a concrete floor and join them together there. Don’t. The heat from a welding torch is so intense that it will vaporize the moisture in the concrete, sending a flash of steam right at you or even dislodging a chunk of cement that, under pressure from heat and steam, will fly at you like a bullet.
Do your welding on a welding table or by using proper supports.
Types of Welders
Stick Welding – if all you want to do is simple repairs or basic jobs like joining angle iron together, then this is all the welding you need to learn. Also known as shielded metal arc welding, good systems can be bought new for under $100. This process uses an electric arc that makes direct contact with the metal. The heat of the arc is adjusted by setting the power level, which normally runs from 30 to 225 amps for a basic unit. Lots of farmers are old hands at using these kinds of welders to repair plow blades and other equipment, and perhaps one will show you how to do it if you ask him nicely.
Oxy-Acetylene Gas Welding
This is truly the old-school approach to welding. It offers the advantage of affordability; used rigs are plentiful on sites like craigslist.org as well as in local trade papers. And having one gives you the ability to both weld and cut metal.
One thing to watch out for is the age of the tanks, which must be recertified every 10 years. A used set might need to be recertified, which can be done at a local welding shop. Or you can simply rent tanks form the same store.
MIG/Flux-Core Wire-Feed Welding
This is perhaps the most common type of welding rig you’ll see in auto shops. It relies on a wire feed as well as an inert gas such as argon to complete the weld. A used 120 volt setup will set you back about around $150-$200, not including the gas bottles, which can be picked up at a welding shop.
Making Your Welding Rig Portable
You will probably want a cart to put your welding tools in, so you can take them to the site where the work is being done. These need not be fancy or expensive. In fact, you can buy a cart for $50 or so from Harbor Freight Tools (www.harborfreight.com) . Normally I wouldn’t recommend Harbor Freight as a source for equipment, but they’re not bad at all when it comes to basic items like this one. In addition to their website they have stores in most large to mid-size cities. They’re fun places to browse around, with thousands of items of varying levels of quality.
Wrapping Things Up
I hope you’ve enjoyed this series on putting together your own auto shop. For more information on specific topics, check out the great selection of books available at www.performanceparts.com. Feel free to email or call us with any questions, and best of luck with your automotive projects!
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