I want to learn to weld, then end up building my own rear bumper: Where do I start?

[theoutbackdream]

So I've never tried welding before, other than watching my buddy weld up his seat brackets for his 510. But I've gained some interest in building my own rear bumper, and possibly a few other things after seeing the limited options there are for my 4th gen.

(correct me if i'm wrong here)
That led me to where i'm at now. After learning a bit about welding via the interwebs, it seems the cheapest/best route for a noob like me is to start with stick welding. Depending on the rod you use, it will be more than enough to get the job done, without having to break the bank on an expensive setup, like MIG and TIG. From my research, E7018 rods are the rods I'd want to use for something of this application for it's high tensile strength, of 70,000lbs. Is this correct or should I be looking at different rods?

If E7018 rods are indeed the rods I'd want, what kind of amp welder should I be looking at to purchase?

Fast forward to having all this equipment to weld, experience and materials(luckily, one of my closest buds owns a sheet metal shop, so he can get me sheet metal at cost and cut it for me). I'm ready to build a rear bumper...

How will I know that the weld has penetrated 2 pieces of metal enough to be strong enough to hold?

Is there a certain way I'd need to build the hitch and D-ring shacke mounts, to make sure they won't fail or be a deadly projectile?

I'm sure more questions will come.

 

[ndcent]

Personally I’d pass on stick and get yourself a MIG machine, doesn’t have to be expensive - if thrift is important I’d look for a Hobart on Craigslist, Miller owns Hobart. My first MIG machine was a Hobart 190, it was maybe $450. 220v and took the 11lb spools of wire. Skip the flux core and get a gas bottle.

I’d then work on a variety of smaller projects, welding table, mig cart, misc garage improvements before you jumped into a bumper.

If your welds look good and you’re welding at the recommended settings for your material I’d generally feel confident about integrity. For shackle mounts I’d do root passes and really lay it on.

Welder aside, there’s a whole bunch of other tools you’re going to need though your sheet shop buddy may have you there.

My best welding learning advice is simply to weld. Get away from the computer and lay some wire down, MIG is very intuitive, immediately apparent if your settings are too low, wire speed too fast, forgot to turn gas on, etc.

 

[Vansnxtweek]

^^^^ I have to agree. Go straight for the MIG. So much cleaner and pretty forgiving setup. Def. take the time to make a cart, some other creative projects and you will start figuring it out.

 

[MN4runnerman]

Find a High school that offers community education classes for adults after school. They do everything from welding to home economics classes.

 

[BrianSD_42]

Find a High school that offers community education classes for adults after school. They do everything from welding to home economics classes.

THIS

Also check out low cost community college options.

 

[Inv4drZm]

Even if learning with stick is the 'best' way to start, you will quickly want to jump to MIG, it is super easy and you can weld a bunch of stuff with it. Stick is good for farmers that need to fix stuff in the field with uncleaned metals.

For shackle mounts, you will want to design it so the mounts go through the skin and are welded to some sort of frame behind the skin so you are pulling on something structural and not just the flat face of the bumper.

As for strength assessment. Practice, practice, practice first. It's not difficult to know what a strong weld looks like, it's practically like hot glue for metal. Practice on identical metals to your bumper just prior to welding the bumper to dial in the machine and your technique, and beat the practice pieces with a hammer to double-check strength if you want.

 

[theoutbackdream]

Personally I’d pass on stick and get yourself a MIG machine, doesn’t have to be expensive - if thrift is important I’d look for a Hobart on Craigslist, Miller owns Hobart. My first MIG machine was a Hobart 190, it was maybe $450. 220v and took the 11lb spools of wire. Skip the flux core and get a gas bottle.

I’d then work on a variety of smaller projects, welding table, mig cart, misc garage improvements before you jumped into a bumper.

If your welds look good and you’re welding at the recommended settings for your material I’d generally feel confident about integrity. For shackle mounts I’d do root passes and really lay it on.

Welder aside, there’s a whole bunch of other tools you’re going to need though your sheet shop buddy may have you there.

My best welding learning advice is simply to weld. Get away from the computer and lay some wire down, MIG is very intuitive, immediately apparent if your settings are too low, wire speed too fast, forgot to turn gas on, etc.

Why do you recommend passing on stick and getting MIG?

MIG to me seems like a hassle from what I'm reading, especially to get setup. And the tools, I assume you're talking about are just more things to add to the cost.

I'll definitely look into smaller projects first and work my way up from there. There's no way I'd trust myself to build a bumper first. LOL

 

[theoutbackdream]

Find a High school that offers community education classes for adults after school. They do everything from welding to home economics classes.

THIS

Also check out low cost community college options.

Will be looking into classes that teach welding. My University does have a welding class... I'll have to stop by..

 

[theoutbackdream]

Even if learning with stick is the 'best' way to start, you will quickly want to jump to MIG, it is super easy and you can weld a bunch of stuff with it. Stick is good for farmers that need to fix stuff in the field with uncleaned metals.

For shackle mounts, you will want to design it so the mounts go through the skin and are welded to some sort of frame behind the skin so you are pulling on something structural and not just the flat face of the bumper.

As for strength assessment. Practice, practice, practice first. It's not difficult to know what a strong weld looks like, it's practically like hot glue for metal. Practice on identical metals to your bumper just prior to welding the bumper to dial in the machine and your technique, and beat the practice pieces with a hammer to double-check strength if you want.

Why would I want to jump to MIG? It just seems a bit more of a hassle with more parts/things needed to get a weld down. Stick just seems simple and straightforward. Have some sticks, the Welder, and you're set.

That makes sense, to have something structural behind holding the shackle mounts/tow points.

Guess i'll just need to start welding :thumbsup:

 

[96RedRunner]

[MENTION=157695]theoutbackdream[/MENTION], I learned how to weld by buying a book on welding.
With all the info on the web now days without buying the book you could learn how. I have nothing against welding schools, you do the research you can find out all you need to know free. The money you spend on welding school can buy the equipment you need.

As for how to design what you want to build, copy things that are already built. Study how things are
designed for strength put it together with the look you want.

Since you have a buddy with a welder, go buy some beers n burgers n get with it after doing some research
on laying a bead and welder settings.

 

[ndcent]

Why do you recommend passing on stick and getting MIG?

MIG to me seems like a hassle from what I'm reading, especially to get setup. And the tools, I assume you're talking about are just more things to add to the cost.

I'll definitely look into smaller projects first and work my way up from there. There's no way I'd trust myself to build a bumper first. LOL

As remarked stick is messy farm repair type welding or pipeline work.

MIG is a trigger to pull. Once you’re adept it’s just like a damn hot glue gun, sure there is a lot of technique or finesse to it but still. No set up, get a machine that takes the 11lb wire spools are you’ll rarely have to change it (which is easy anyways.)

 

[Inv4drZm]

Why would I want to jump to MIG? It just seems a bit more of a hassle with more parts/things needed to get a weld down. Stick just seems simple and straightforward. Have some sticks, the Welder, and you're set.

That makes sense, to have something structural behind holding the shackle mounts/tow points.

Guess i'll just need to start welding :thumbsup:

If your eventual goal is to weld bumpers and similar equipment I really think you should get a MIG. It does all the wire feeding for you, just set the wire feed and voltage according to the chart on the inside panel. It's what the pros use and I think it'll be a cleaner weld.

For 'support' tools you will need at least one grinder with cutoff wheels and sanding wheels, welding mask, welding gloves, welding cart, clear face shield, vise/clamps, metal welding table, welding magnet or square. Crappy long-sleeve shirts.

 

[ndcent]

I don’t know any fabricators who would build a bumper or anything else with stick.

..trying to make it more succinct for you here.

 

[theoutbackdream]

[MENTION=157695]theoutbackdream[/MENTION], I learned how to weld by buying a book on welding.
With all the info on the web now days without buying the book you could learn how. I have nothing against welding schools, you do the research you can find out all you need to know free. The money you spend on welding school can buy the equipment you need.

As for how to design what you want to build, copy things that are already built. Study how things are
designed for strength put it together with the look you want.

Since you have a buddy with a welder, go buy some beers n burgers n get with it after doing some research
on laying a bead and welder settings.

Buying a book could work, but I feel that school will give me some small/fine details that someone with experience can give me. But you're not wrong.. Welding school can buy the equipment I need.

 

[theoutbackdream]

If your eventual goal is to weld bumpers and similar equipment I really think you should get a MIG. It does all the wire feeding for you, just set the wire feed and voltage according to the chart on the inside panel. It's what the pros use and I think it'll be a cleaner weld.

For 'support' tools you will need at least one grinder with cutoff wheels and sanding wheels, welding mask, welding gloves, welding cart, clear face shield, vise/clamps, metal welding table, welding magnet or square. Crappy long-sleeve shirts.

After reading the comments, I think i'll look into MIG a bit more. The upfront cost seems incredibly high, but from what's been said, it seems like the cost would be well worth it..

 

[theoutbackdream]

I don’t know any fabricators who would build a bumper or anything else with stick.

..trying to make it more succinct for you here.

You've got a point...

 

[Doc2012]

I’m about to open a can of worms here, but this is MY story.

I got into welding when I got this rig.

At the time, I was living in the barracks, and didn’t have jack shit, not a place to do jack shit.

I started hanging out at the body shop, and picked up welding from the old timers that were there.

They were awesome, and helped me get started.

Still not having a true grasp on it all, I decided to watch some YouTube videos, and got some balls.

Stick welders have their place, as do MIG and TIG.

I opted to stick with the MIG. To me, it’s easier to control, and cleaner.

I got one of the HF 90 amp flux core welder to play around with. For ~150, it seemed worth it too me.

And it kinda was. After a little bit, I had some pretty decent welds, for flux core, and I got balliser, making more and more stuff.

I wouldn’t trust it to do anything more than 1/8” steel, however. And it tends to burn through anything thinner than say 20ga, and that’s being careful.

Now, my brother has a MillerMatic MVP211. That thing is TITS. It’s 120/240v, and can weld at least 3/8” thick steel, and down to like 24ga.

I’m renting the house I’m in right now, which is why I haven’t gotten a Miller welder, or equivalent, but as soon as I get my own house, which will hopefully be within the next year, I’m getting a Miller or Hobart welder.

I’ve been looking at some other 120v welders, and, Eastwood has gotten my attention as well. Just in case I can’t get out of this place soon.

They seem to be pretty decent, and are flux/MIG.


I guess the point I’m trying to make, figure out if you actually LIKE welding or not.

Hook up with someone that has a welder near you, and see if they’ll let you get a little bit of burn time. Or, go to HF and get the cheap flux core and make some stuff. Just nothing too thick.

Once you’ve figured out if you like it or not, get a better welder. If you own your own place

I made a ladder out of 16ga square tube, and 16ga plate. It seems to hold my 230lbs bouncing on it just fine. And I made it with the HF flux core.

It’s frustrating at first. Trying to get everything right. Wire speed, amperage, stick-out. Making sure the materials are clean enough, keeping the temp of the metal low enough to not burn through, but making sure it’s hot enough to get good penetration.

Sorry I bounced all around.

Just some thoughts.


Sent from my iPhone using Tapatalk

 

[96RedRunner]

You've got a point...

Stick for making a bumper is like using a framing hammer for finish trim work.

[MENTION=76419]Doc2012[/MENTION] made good points, is similar to how I started.
Going to welding school will show you the basics, the real learning comes from
trial and error of building things.

Hang with your Bud that has welder, get your feet wet, go from there. My $.02

 

[theoutbackdream]

I’m about to open a can of worms here, but this is MY story.

I got into welding when I got this rig.

At the time, I was living in the barracks, and didn’t have jack shit, not a place to do jack shit.

I started hanging out at the body shop, and picked up welding from the old timers that were there.

They were awesome, and helped me get started.

Still not having a true grasp on it all, I decided to watch some YouTube videos, and got some balls.

Stick welders have their place, as do MIG and TIG.

I opted to stick with the MIG. To me, it’s easier to control, and cleaner.

I got one of the HF 90 amp flux core welder to play around with. For ~150, it seemed worth it too me.

And it kinda was. After a little bit, I had some pretty decent welds, for flux core, and I got balliser, making more and more stuff.

I wouldn’t trust it to do anything more than 1/8” steel, however. And it tends to burn through anything thinner than say 20ga, and that’s being careful.

Now, my brother has a MillerMatic MVP211. That thing is TITS. It’s 120/240v, and can weld at least 3/8” thick steel, and down to like 24ga.

I’m renting the house I’m in right now, which is why I haven’t gotten a Miller welder, or equivalent, but as soon as I get my own house, which will hopefully be within the next year, I’m getting a Miller or Hobart welder.

I’ve been looking at some other 120v welders, and, Eastwood has gotten my attention as well. Just in case I can’t get out of this place soon.

They seem to be pretty decent, and are flux/MIG.


I guess the point I’m trying to make, figure out if you actually LIKE welding or not.

Hook up with someone that has a welder near you, and see if they’ll let you get a little bit of burn time. Or, go to HF and get the cheap flux core and make some stuff. Just nothing too thick.

Once you’ve figured out if you like it or not, get a better welder. If you own your own place

I made a ladder out of 16ga square tube, and 16ga plate. It seems to hold my 230lbs bouncing on it just fine. And I made it with the HF flux core.

It’s frustrating at first. Trying to get everything right. Wire speed, amperage, stick-out. Making sure the materials are clean enough, keeping the temp of the metal low enough to not burn through, but making sure it’s hot enough to get good penetration.

Sorry I bounced all around.

Just some thoughts.


Sent from my iPhone using Tapatalk

This has probably been the most honest post i've read in awhile, and a good post. Thanks for that.

I might just go a similar route as you. Pick up a cheap welder like the HF one, and give welding a shot. Hearing about how frustrating MIG welding at first was, was exactly the reason why I wanted to hope over to Stick welding, but this thread has convinced me to just jump to MIG. I hope it won't be as frustrating as it sounds... But.. It'll be fun.

 

[theoutbackdream]

Stick for making a bumper is like using a framing hammer for finish trim work.

[MENTION=76419]Doc2012[/MENTION] made good points, is similar to how I started.
Going to welding school will show you the basics, the real learning comes from
trial and error of building things.

Hang with your Bud that has welder, get your feet wet, go from there. My $.02

Yea, I'll have to hang with my buddy that has a welder and learn from him.

Or I might just opt to pick up a HF welder and just go from there. haha