Is there a possible ground issue with the part the plug weld is not sticking? A good ground on both parts is important. I've brushed it down to get all the mill scale off and the clamp is holding the 2 pieces together. I think that is a good ground. Based on Jody's charts, you target would be, .059...

That's a good idea. I never thought about cutting a flange like that as that's the first I've ever heard of it and I've read A LOT on this topic in the past week. I'm gonna try with this without drilling any holes and see how it goes: Spot Welding Nozzle If that doesn't work out, I'll try your sugge...

I have just about every cheapish tool HF sells including the step drill bits. 10 of the 27 LED lights, 8 tape measures and more 9 LED flashlights than I can count. I think I have one in every drawer in my house :D I'm actually using the air punch/flanger from HF to make my holes. It's 100% faster th...

I haven't done a lot of plug welding but when I did it was where I cut out spot welds in sheetmetal and the holes were about 3/8 to 1/2" and I had to clamp the 2 peices tight together to do a nice job. When you say they're 1/4" apart, I hope you're talking about spacing between each one a...

BTW Hope this doesn't sound preachy, just trying to help out. Not preachy at all. I welcome any and all comments. I worked on it a bit last night trying to fit my replacement pan into place. It involved a lot of persuasion with a BFH but it's close. I also got a sheet of 14 ga and tested laying bea...

Yes, I did. I printed out the whole manual and read it cover to cover.

Ok, so I gave up on Flux core and got a bottle of 75/25 and converted to MIG. Now the issue that I'm facing is doing plug welds. I can't get enough penetration and it just blobs up. I've tried adjusting both wire feed and voltage but it doesn't seem to help. I'm starting in the center and swirling a...

I mentioned this is my Intro thread but thought it would be best to start a new one here. I have an 05 Nissan Altima that has the floorboards completely rusted through. It's a common problem because of an HVAC drain line that gets clogged up. Anyway, I'm going to cut out the rust and weld in new met...

Thank you Steve. I really appreciate your input. What kind of seam sealer would you recommend? I have some rubberized undercoating in a rattle can that I was going to spray on the outside. Would that be Ok for the inside too?

I've only done a little bit of stick welding with a cheapo welder from Harbor Freight. I mainly burn 6011 or 6013 on mild steel. Now, I have a delima. My 05 Altima has a very common problem where the floor boards rust completely out. Mine are so bad, the only thing between my feet and the road is a ...