Welding Tips and Tricks

I'm reworking my wrought iron driveway gate and I started by trying to do some simple changes on the gate in place. I pulled my MM211 (transformer-based) and tried to tack a few spots while running on 110V. (75/25 mix, 0.030" ER70 wire) The machine sounded sad/puny, the arc was weak, and I had a difficult time making a decent tack. (not a shielding problem) I tried the machine on 110 (same extension cord) in my garage and it seemed fine. I suspect the outlet I am using at the gate is a long run from the breaker box and I'm getting a lot of line voltage drop.

I have since pulled the gate off of its hinges and will weld the entire gate in my garage where I have 220V. The trouble is I need to move my automatic gate closer mounting tab which is welded to the 4x4 sq. tube post at the driveway. I'm trying to figure out how I'm going to get a few inches of weld laid down considering the power issue.

I'm wondering which process (or machine) would use less power? flux-core wire VS stick OR MM211 VS AHP200X (stick mode)

I've never stick welded but there's only a tiny amount to be done in a lightly loaded, non-critical location. Why not learn?

steve

I'm guessing the AHP, being an inverter machine, will have a lower draw than the Miller 211. If you have the manuals for both machines, the current draw should be listed in the specs. You're also probably right about voltage drop at the gate outlet.

I think you're right, an inverter should be much more efficient at the conversion process. I also looked at Miller app and if I understand it correctly, the voltage and current required for a stick weld is lower than FCAW.

I have a suspicion my ground may not have been as good as I thought at the time and I know that all bets are off if the ground isn't solid. I may give it another try with a secure ground and may even try a different outlet if I can find one.

Still open to other ideas... chewing gum, bailing wire, superglue.

steve

1/16" rod

DLewis,
Your suggestion of a small diameter rod gave me an idea. Before switching to stick, I'm going to ensure I have a good ground and use 0.024" wire. We'll see what happens.

I made sure I had a solid ground nearby. I switched to 0.023" solid ER70 wire.

Results?
The MM211 was much happier than previous attempt; however, the weld was still pretty cold. I stood on the tab and it held. Would I trust my life to that weld? heck no! In this particular application the worst thing that can happen if it fails is my gate won't open or close and my wife will have to get out and move the gate for me

In hindsight I probably could have TIG'd it.

steve