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For the complete beginner.
Learn to Arc Weld in 10
Make your own tent for the Jeep Cherokee XJ.
To make the tent for the Jeep Cherokee XJ in an afternoon, you will need a small arc welder, sometimes called an "inverter arc welder" and some 2.5mm diameter electrode rods, a welding helmet, gloves, chipping hammer and wire brush. I have taught all ages, even my own son learned to arc weld at 10 years old.
The skill is a steady hand.
This simple guide describes “How to Arc-Weld Item [L] the jeeptent roof
support socket, to Item [A], the jeeptent Roof support right, using a 90 amp
minimum Arc Welder, or better still you could buy or hire a small Arc Welder
Inverter for the day.
Now to start welding:
clamp two bits of 2mm square tube together ( A and L ) on a flat steel plate so they
form a 90 degree
earth clamp onto the item you are welding.
the welder on, set it to 80 amps, please note that the handle holding
the welding rod must not
touch the earth clamp. Keep both apart or they will spark.
welding helmet down over your eyes and tap/scratch the rod in the
groove where they join
at 45 degrees on both planes like below.
will melt very quickly and reduce down in length.
As the rod burns down, draw the rod towards you very slowly, and push the rod “in” gently as it burns down. Move the rod away from the weld which you have just laid.This picture above shows the right angle to hold the rod at all times.
slower you travel the better. As the rod gets shorter you will need to stop and
bend the rod up a little, to keep the same angle of approximately 45 degrees or
goggles, chip off the slag coating on the weld, and then wire brush the weld to
give a good finish.
First practice weld on some 2mm thick scrap steel using 70,80 & 90 amps.
When ready to weld, clamp tube [L] at 90 degrees to tube [A] on a flat metal plate with two “G” clamps. Lift tube [L] 2mm off the plate with metal packing. It will now be positioned centrally. Attach the earth clamp from the welder directly to the job.
finished weld should look semi-circular, about 4mm wide and uniform,
item is square. Turn job over, clamp down tight and weld other side. Then weld
the last two sides. Keep checking item is square and not tipped over at an
Arc-Weld Item [P] the leg socket to item [G1] leg bottom
Marking out and cutting detail of the 2012 model roof socket, this is how you
make out and cut the joint, use a bit of spare square tube to mark the white line
How to tell a good weld.
A good weld should look Bright and Shiny, not dull and burnt.
It should be uniform in width and height along its length.
It should have slight ripples width ways.
It should penetrate the job and have no discernible undercut, for example it should not look like a pencil laying on a table
It should not be thin and stringy.
It should be semi circular on the upper surface not flat
The slag should come away very cleanly, if not, this points to cheap rods, or the amps are too high.
If you were to put a test piece in the vice, and hit it with a hammer, it will not break at the weld.
and tee welds must be concave (hollow) not convex (curved out)
If the rod is sticking to the part you are welding,
then run through this list of solutions.
How to tell a bad weld.The slag will
stick and not want to come off.
The weld will be thinner than 4.00 mm when using a 2.50mm rod.
The weld will not be bright, but burnt and a dull blue .
The weld will not be uniform in shape along its length.
There could be slag stuck in the weld, & splatter everywhere.
The 2012 model in its rough stage.
If the bead of weld too thin
If the bead of weld is too wide.
Keep the rod steady and do not
weave from side to side, try holding your breath, or move the rod a bit
quicker, and do not feed in so quickly.
If the arc flares up wildly.
Then keep a constant smaller gap between the job and the tip of the rod, you are creating too big a gap between the rod tip and work piece. Touch the job.
Are you using the right amps for the right rod, you could be using too many amps, an indication of this would be splatter beads on the job.
Are you moving the rod away from the molten pool, not into it. It is like holding the rubber on the end of a pencil and dragging the pencil along. It is also like putting mastic sealant round a bath with a mastic gun, you run away for what you lay down.
The skill is in;
Parts Laid out and "jigged up" for welding. This is the jeeptent 2012 model for
the more advanced welder.
Here are all the Jeep tent 2012 parts laid
out next to a shovel so you can see
the scale, its so easy to make with very few welds.