- Welding Set Up -

This is the welder and welding supplies that I started with as a beginner and the process I followed to lay my welding first bead.

Welder

Hobart Handler 140

I went with a Hobart Handler 140 because it is a 115v, as I dont have a 230v outlet in my garage. It was in my price range of about $500 and is well reviewed. My local Tractor Supply had it on sale, so that sealed the deal for me.

Tools/Supplies/Accessories

Gloves
Sleeves
Hood
Magnets
C-clamps
Welding Clamp
Grinder
Grinding Wheels
Flap Disks
Cutting Wheels
Chipping Hammer
Welding Pliers
Nozzle Gel
Welding Blanket

Process

Flux Core

I decided to try flux core since I could start welding right away without the need to buy gas. The welder comes with flux core wire but does not come with a flux core nozzle.

Welder Setup

Spool tensioner

You want it just tight enough to keep the spool from moving when you let off the trigger, even at the highest wire feed speed. Dont make it too tight either or you make it harder for the drive wires to pull the wire.

Drive Roll Mechanism

They are spring loaded and pop right off. One side is knurled for flux core and the other is smooth for solid wire. You need the correct size drive roller for the size of wire you are using.

Retracting Wire

Take off the drive roll tensioner and just manually move the wire wheel to retract wire.

Drive Roll Tension

You want it just tight enough that you cant stop the wire with a glove on. You can slow it down but not stop it.

Changing Polarity

Make sure the wire going to the power block is the correct one. Electrode positive for solid wire. Electrode negative for flux cored wire.

Ground Clamp

Mig welding machines need a really solid ground. Not a intermittent ground. The Handler 140 does not detect if you lose ground it will keep feeding wire and you get the drive by shooting sound. Rough starts and stutters are a result of a loose ground.

Source Practice Metal

For practice, I’m aiming to source all my metal from free sources. Offerup and Craigslist are good sources for people giving away scrap metal.
I found 1/8″ flat bar dumped in the desert.

Prep Metal

The practice metal I found was a long piece so I cut it down into more manageable pieces with a cutting wheel and used a flap disk to grind off the paint and get down to shiny medal.

Safety & PPE

Test if auto darkening is working on helmet
Wear eye pro under helmet
FR jacket
Backwards Hat – bill protects hair
Hair Tied
Fire Extinguisher close by
Be aware of where spatter may land
Remove any flammable objects from the work area
Fan blowing
Garage open for ventilation
Welding blanket to shield bye standers from arc

Helmet Settings

Dial in your shade setting, I started with 9, as thats what it was set at and it was way too low.
Flux core welding is brighter and needs a higher setting
I now set it at 11

Ventilation

Im in a garage, so I leave the garage open along with blowing a household fan over my workpiece to move smoke away from my face. I also have an overhead air filter running that sits directly over my work area.

Machine Settings

Measure metal thickness
Look up on chart for recommended settings based on welding process, wire size and metal thickness
Set wire speed and voltage dials accordingly
Plug directly into outlet(20amp ideally) not extension cord

Setup Work Piece

Make sure your workpiece doesnt move while your welding on it by either clamping it to the welding table, using magnets to hold it in place or placing a heavy object on top of it.
Connect ground to workpiece or table if it is metal

Stick Out

Is controlled by how close the contact tip is to the end of the nozzle. Flush or sticking out a bit is good for the most part with mig welding. Longer stick out for flux core. See what the wire manufacturer recommends.
I used a stickout less than 1/2″
Trim with welding pliers if too long

Technique

Pulling or Dragging

For flux core welding you must use a drag technique to let the slag form behind the weld. If you push it, you could get slag into the weld.

Exercise

Running Straight Beads

First exercise I did was getting comfortable with laying straight beads on a flat piece of metal. I did a straight drag to start out but found that doing cursive e’s allowed me to maintain a straighter line.

Practice Runs

Take some dry runs experimenting with body position and hand positioning so you can find a comfortable one
Practice your hand propping and being able to smoothly move across your workpiece

First Contact

That first spark is daunting, remember to keep a consistent distance between your gun tip and the work piece. You’ll probably instinctively pull away on your first experience with an arc and the spark, so just be mindful about keeping the distance close or try not to flinch.

Watch Puddle

Let the puddle be your guide as to how fast you should be moving. It should be forming uniformly before moving along. Get a good head position and angle to see the puddle better. A good light source to illuminate the weld also helps tremendously.

Maintain Speed & Distance

Mind your travel speed and keep it consistent along with your stick out.

Clean Slag

Use a chipping hammer and a wire brush to clean the slag off your welds, or an angle grinder with a wire wheel can accomplish this in one step.