Hello All,
I am a newby to welding and am having alot of trouble. I have a Lincoln Electric Weld Pac 100 solder core wire feed welder. My problem is that I keep blowing holes in my metal. <img src="/forums/images/graemlins/scared.gif" alt="" /> I am repairing some rust spots in the bed of my 1987 Toyota 4x4 p/u. I want to do some other metal work on the truck as well, but need to find out why I'm blowing holes. <img src="/forums/images/graemlins/confused.gif" alt="" /> PLEASE HELP!!!!!!!!!!!!!! [img]http://http://www2.snapfish.com/slideshow/AlbumID=55303174/PictureID=2440071094/a=60240938_60240938/t_=60240938[/img] [img]http://http://www2.snapfish.com/slideshow/AlbumID=55303174/PictureID=2440071094/a=60240938_60240938/t_=60240938[/img]

Sorry about the pictures, maybe this will work.

your link isn't working.
Try turning the numerical setting down on your welder.. It should have a guide for settings based on thickness of the metal.

Other than that, welding on sheet metal is a real PITA. Most of the body work guys I've seen start with tacks. IE - a spot here, a spot there. They fill later with a TIG. Filling heats up the metal and tends to warp it... I'm suggesting that the best way to do it with a budget welder setup is going to be to cut out the offending metal, fill with new patches as appropriate (consider counter sinking instead of what you're trying to do), spot weld, - and then fill with a fiberglass resin based filler (not bondo). Dynaglass comes to mind.

My brother built a gas tank with a MIG, it's possible to do but takes some practice.

A flux core welder makes pretty ugly welds anyway! You'll be amazed if you ever use a decent mig at how much cleaner and easier it is.

What size of fluxcore filler are you running?

What grade of filler are you running?

If you are attempting this with the 0.035" E71T-11 filler that came with the machine it is going to be a hard task, basically the machine should be at the lowest voltage and wire speed settings on the machine and some quick tacks jumping around a lot.

Ideally you would use a gas shielded 0.023" hardwire filler with the MIG conversion and a cylinder of sheilding gas.
Barring that going with a smaller self shielded fluxcore filler size such as 0.030" would make life simpler.

I've used both quite a bit(flux core and gas MIG).....What you are doing requires gas and 023 wire....flux core is too thick(030 or 035) and burns too too hot.

agreed with ZUK...if your using Gas which im guessing you are make sure there isnt alot of wind too, weld in a garage with the doors closed...

Tack a half inch at a time then move to another spot to allow it to cool down...

Thanks All.
I guess I am going to have to invest in the gas attachment.
I am trying to use just the flux core wire and no gas and that is obv. not working. Will a Map gas setup work? <img src="/forums/images/graemlins/cheers.gif" alt="" />

No, the welder has to be able to be set up for either CO2 or argon/CO2 mix. Read the instruction book and see if that set-up is possible on your welder. I looked on the Lincoln web page and did not see that welder listed on there product page.

co2 also is hotter than a mix. Since the pics don't work (at least for me)I can't sat for sure...but, if you're trying to fill in a hole, that's the hardest thing to do. Try going around the perimeter and filling the hole in that way, use a copper backer (the weld wonÆt stick to it and itÆll act as a heat sink) or make a patch. What ever you choose, just make wee little tacks until the area is filled.

Don't forget to change your nozzle tip if you change wire diameter. My HF 90a/110 mig welder came with a 2 different ones...25 and 30. 35 must be for the big boys.
I agree...spot weld a inch or so before the metal gets to hot and punch a new hole in the metal.
Mike



I'm no welder just from experience.