Welding always fascinated me. The idea to be able to just build whatever I wanted or needed sounded like a dream. Plus, when I was learning I didn't have the money or resources to take my car to a shop everytime I needed some little thing welded. In my opinion, welding is a science, an art, a discipline, and a skill all in one. It is a real pain in the ass to learn, but it pays dividends.
This post will be dedicated to explaining the not so commonly known things that anyone who you talk to about welding will expect you to know.
Metal Types
Very basic guidelines limited to the common metals used on racecars.
Ferrous Metals - Mild Steel, Stainless Steel, Chromoly
Contain iron.
Are Magnetic
Will rust due to high carbon content
Stainless Steel is an exception to the rust rule because of the chromium put in it. However, It will rust if not welded properly.
Non-Ferrous Metals- Aluminum
Does not contain iron
NOT magnetic
Will not rust
Welding Types
Stick Welding
no clue, never used it & I never will on a car
MIG (Metal Inert Gas) - Mild Steel
REQUIRES GAS - hence the G in MIG
Gas is a mixed C02/Argon
Uses a gun to feed your filler wire into the puddle. This makes it easier than TIG, but you have less control of your puddle.
Have personally only ever used it for mild steel and only recommend it for mild steel. I did booger some stainless v-bands to mild steel tubing on my first turbo kit (seen above) and it worked, but not ideal.
The spools of wire come in different thicknesses that must be matched with the tips of the gun. Your welder should have a chart on recommended wire size and welder settings based on the thickness of the material you are welding.
TIG (tungsten inert gas) -
Requires gas - again g in tig
100% argon
Two Settings- AC/DC (đ¤đź)
DC (direct current) - amperage is a flat line. Used for mild steel, stainless steel, chromoly
AC (alternating current) amperage is a sine wave. Used for aluminum.
Tig torch - used to create arc, which makes your puddle, and flows shielding gas
Tungsten - lil pointy guy inside the torch that makes the arc. You'll want a different tungsten type depending on ac/dc
Filler Rod - your filler rod type will be melted into your puddle, so the metal you are welding will determine the filler rod you need. Thickness of filler rod will also be different depending on task.
Setup & Tank Safety
Whenever you are welding (MIG or TIG) you need a ground clamp on metal connected to the piece you are welding. If you are really dedicated to learning, Its a great idea to build yourself a table. I use my table for strictly TIG (no splatter all over) and I just leave the ground of the welder attached to the table (which the part I'm welding is sitting on) so I don't need to ground every part.
BUY A WELDING CART. I suggest the carts with drawers so you can stay organized, but they are more expensive. There is a reason the tanks get strapped to the carts. If the tank falls over and the valve breaks, that compressed gas will turn that tank to a skud missile. If you haven't seen videos, I suggest watching some because its wildly entertaining. That being said, while figuring out transportation of the tanks to and from your house, safety should be critically considered as well.
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