This said - while really a simple project to put together now that I've built a jig and bought a bunch of clamps - there's one part that keep causing me trouble - and I could really use some input from the experienced guys out there to see how I can improve.
1) There's a gap in these parts created by the curvature of 2x6 1/4 wall tubing edges - where 1/2" plate presses up against. Before the jig I was doing this the long hard way going vertical up z-weave....the fillet seemed to fill the gap.
Now I'm welding with the past flat on ground, and finding that when I fill the gap (1/8 7018 125-1230 amps), the slag is epic to chip out on the first pass...no wormholes noticeable on surface however....but I wonder what's going on down below in the root One the first pass in that 'valley' - successive passes at 130 - the slag peels off mostly on its own with zero trouble. What's the trick to handle this kind of situation?
2) Once the assembled part is in position - there's one more valley where the 2x6 1/4" wall tube meets the top rails - which are 1/8" or often less (!!) rolled sheet metal - and i have to go vertical up here. I back the amperage off, but all too often burn through and later have to fill that. Not having much better luck trying to deal with it using flux core mig either. Best ASTHETIC results so far using 3/32 7018 circa 80-85 amps as I can jam it in there a little better on the weave. Second pass back to 1/8 and a little more heat, pausing longer on the 1/4" of course.
Be most grateful for some input from guys with real world field experience on this one - while classes and certs would be great, I've got no choice but to jump in and get this kind of thing done - and done well - clearly strength important for this upgrade.
PS- Jody, if you're reading this one by chance - thanks for all the tig videos - they're great. Devouring late at night in preparation for arrival of first ac/dc Everlast unit - be most helpful in my line of work. Appreciate what you do.
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