Welding Complete, 2nd Edition: Techniques, Project Plans & Instructions

Contents

Introduction

Welding is a practical skill that is challenging, rewarding, and also great fun. We encounter welded items throughout our daily lives and activities—they are practically infinite. The appliances in our home, the railing on your porch or stairs, our automobiles, the bridges and infrastructure we drive on, the structure of the buildings we work in, and even our computers. Welding makes everyday tasks more manageable. Welding can also bring joy to a craftsman making items for use in the shop, home décor, and outdoor living and décor.

Basics

The costs involved in setting up a well-equipped home welding shop are comparable to setting up a well-equipped woodworking shop. A knowledgeable welder with the proper equipment has a great advantage, because the projects and repairs he or she can accomplish are too numerous to count. The availability of numerous inexpensive materials is also key to being creative. From basic repairs, to building your own shop tools and work stations, to creating items you can sell—the possibilities with welding are only limited by your imagination and experience. Always striving to learn and improve your craft lets you experience the “wow” factor when others see and admire your work.

Techniques

In this chapter we will discuss the basic cutting and welding processes. These techniques are the foundation of your skill set as a welder—skills you will use again and again, regardless of the type of welding you pursue. This chapter also provides basic directions and step-by-step photos that illustrate major welding and cutting processes. You will find quick reference charts that describe electrode selection and filler wire choices, metal types and weldability, and joint design and weld types.

Contents - Welding Projects

Shop

Home Décor

Outdoor Life

How To Build A Coat Rack

Make The Hooks & Frame

(Step 1.) Cut the hooks (A) to length. (Step 2.) Clamp one end of each hook to a 2"-diameter pipe with a vise-style pliers. Bend the bar a half turn around the pipe to create each hook. (Step 3.) Weld each of the two mounting washers (B) to the top of two separate hooks. Weld a ball (C) to the end of each hook. (Step 4.) Cut the crossbars (D) to length. Mark the crossbars at 4", 8", and 12". (Step 5.) Align the two hooks that have the mounting washers flush with the crossbar ends. Tack weld in place. Place the second crossbar 4" from the top crossbar and tack weld in place. Check that the angle between the crossbars and hooks is 90°, and finish the welds. (Step 6.) Center a hook under the two crossbars at the 12" mark lining the top of the hook flush with the top crossbar. Check that the angle between the hook and crossbars is 90°, and weld into place. (Step 7.) Weld the remaining two hooks to the crossbars at 4" and 8".

Make The Circles & Spirals

(Step 1.) Cut the circles (E) to length. (Step 2.) Clamp one end of a circle blank to a 4" pipe using a vise-style pliers. Bend the rod around the pipe one and a half turns to form a circle. Repeat to form the remaining circles. (Step 3.) Create the spirals (F) and mini-spirals (G) using a needlenose pliers. Wrap the wire around the end of the pliers to create a circle. Remove the circle from the pliers and grip it in the pliers. Wrap the wire around the circle until the desired size spiral has been formed.

Assemble The Decorative Features

(Step 1.) Place a circle in the space between the first two hooks starting either on the far left or far right end. Squeeze or expand the circle to fit into the space and cut off any extra length. Weld the circle ends together and weld the circle to the two hooks. (Step 2.) Repeat step 2 with the remaining circles. (Step 3.) Arrange three mini-spirals inside the second and fourth circles. Weld them to each other and to the circle at contact points. (Step 4.) Place the large spirals between the remaining hooks and weld in place. (Step 5.) Wire brush or sandblast the coat hanger. Apply the desired finish.