Welding Tips and Tricks

I built a pipe bumper with towhooks for my Jeep. I used 2 1/2" Sch.40 for the build, 1/4" plate for the sideplates, padeyes, brackets and trim pieces. The project took only 1 weekend plus an additional hour for paint. I used my 1984 Miller Bluestar AC/DC gas stick machine, torch and basic handtools for the job. It is a very functional bumper that will get used often where I live in rural Texas pulling folks from the mud and whatnot. I hope to post more project photos as I get time. Thanks for looking.

Here's another Jeep Bumper on a 2009 Wrangler Sahara.
This one is intended for a tow bar connection. The bumper is 3/16 x 2"x5" tubbing.
The tow lugs go all the way through, welded front and back, 1/2" x 3" bar.
It replaces the plastic and sheet metal original.
I used a 225/125 AC DC Lincoln stick.
There is a little more work to do, fill the ends and add trailer hitch socket.
I'll mount the front license plate in the Trailer socket.
I burned up the polarity switch on the welder last week on a near 100˚day burning 1/8 rod.
I've owned three of these welders and it's the first trouble I've had.
Jack

Very nice work, and so functional too. Looks like it will last forever.

cptjackm wrote:

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Here's another Jeep Bumper on a 2009 Wrangler Sahara.
This one is intended for a tow bar connection. The bumper is 3/16 x 2"x5" tubbing.
The tow lugs go all the way through, welded front and back, 1/2" x 3" bar.
It replaces the plastic and sheet metal original.
I used a 225/125 AC DC Lincoln stick.
There is a little more work to do, fill the ends and add trailer hitch socket.
I'll mount the front license plate in the Trailer socket.
I burned up the polarity switch on the welder last week on a near 100˚day burning 1/8 rod.
I've owned three of these welders and it's the first trouble I've had.
Jack

I'm a noob..i have a lincoln 225 ac..i have started to get decent welds with it..got a good deal on a lincoln ac/dc machine yesterday..haven't even plugged it up yet..when and why will i use the dc function..
thanks in advance
tom

http://tomblackart.com/

tom wrote:..when and why will i use the dc function...

tom,

most stick welding is done on DC. Get yourself some 6010 (or 6011) and some 7018. 1/8" rod is a good all around size. Hook it up DC reverse polarity (negative ground, positive electrode).

I do ALL of my stick welding on DC. About the only thing I use AC for is tigging aluminum.

Nice job on the bumpers, guys.

welder689 wrote:

tom wrote:..when and why will i use the dc function...

tom,

most stick welding is done on DC. Get yourself some 6010 (or 6011) and some 7018. 1/8" rod is a good all around size. Hook it up DC reverse polarity (negative ground, positive electrode).

I do ALL of my stick welding on DC. About the only thing I use AC for is tigging aluminum.

Nice job on the bumpers, guys.

thanks a bunch.. that'll get me started in the right direction..i think i have every rod known to man..

Thanks for the comment on the bumper brother.

Cody

Good job, that looks better than some of the ones you can buy for a Jeep. Probably stronger also.

Thank you kindly there, Pelldilky! Take care over in Ireland brother.

Cody