Hello this is easier than you think. I think most people think too much and get confused.
First clean metal both sides (the area where you are welding)if possible.
Second get a piece of scrape metal the same thickest for the metal you will be welding. You will use this to tune your welder.
Third I agree that 0.23 is a nice wire size for sheet metal (although I use 0.30 when I'm out of 0.23)
Forth I will not weld sheetmetal without gas, although you can do it its a mess. The welds are not as clean and flux is too hot for my taste.
I butt weld everything when possible its not hard. Although do what your comfort level tells you.
Tune your welder
This is how you tune your welder hold your gun the distance you will be welding from the metal (this is different for each person I hold my gun as close to the metal as possible) Pull the trigger and the same time turn your wire feed knob until you hear the sound of beacon frying. A nice sizzle. It may to new people a couple of times to get this. If your welder has settings recommendation this is good because it can be on or very close so start there.
Oh I never start a weld with more than 1/4 wire stickout.
Another tip, with sheetmetal keep the metal as cool as possible. Never run a bead, jump around alot with tack welds until you complete the seam. My rule is if I can not touch the metal with my bare hand its too hot to weld. I let it cool until I can touch it. So while one end is cooling weld on the other and so on.
I hope this helps
Last edited by mkabwe; 07/08/2008 11:01 PM.
