[John Chamorro]

I have to build a bunch of galvanized down spouts for a customer. Has anybody welded rather than soldered? If so what filler or wire did you use?

[Otto Nobedder]

Welding galvanized sucks on many levels, and I don't recommend it.

You will destroy the coating in the HAZ no matter what process you use, and will need to treat with a cold-galvanizing spray which will never quite match.

Solder is the way to go.

If you "must", don't even consider TIG. By the time you grind enough inside and out that it doesn't puke on you, you won't have anything to weld. It can be done with MIG with less prep work, but be prepared for the fumes.

Steve S

[John Chamorro]

Yeh,, I've done a shitload of galvanized and it's always a pita. I've always drunk a little milk first, yes it does keep your stomach from getting weird. I was hoping that just maybe someone had some sort of miracle method for doing something other than soldering which I suck at.

[ex framie]

The miracle is PVC downpipes.
Other than that, what Otto said.
Not what you wanted, but it is what it is.
Cheers

[Poland308]

Or SS. Like Otto said if you need to weld it use mig. I used to make transitions for the fans that go on grain bins. They were gavinized and welded solid. Brushing and useing cold galvanized is OK at best.