I am welding a piece of 2" square tube that is 1/8" thick. I am makeing a bend in the tube by cutting a slot on three sides and bending it and welding it up.

The problem that I am having is that I don't have a good way to make the cut a V shape so that the edges all line up with no gap. When it comes to welding it up it will blow a hole in the edges of the gap. I am using a 3/32 6013 rod with the arc welder set to 60A. I tried the 40A setting, but could not get an consistant arc.

My thought is to use a 2" square thin plate ground to the shape of the gap and weld it up. That would make the gaps smaller.

Would a mig welder be able to fill the gap? I don't have any experience using a mig welder.

Any other thoughts? Different rod?

Thanks