Welding,cutting, and pit building tips for the beginner.

k.a.m. · Last edited by k.a.m. on Sun Jul 12 15 1:14 am; edited 15 times in total

Here is a list that I am working on for the beginner welder or pit builder.

This will be a growing list so please feel free to pm me for add on equipment. I have searched the cooker and off topic section for welding threads and I believe I found them all.

I have asked SoEzzy to sticky this in the welding section in hopes
that it helps the new and old pit builders in some way.

Thank You SoEzzy for your help and most of all your patience with me.

Safety first.

(Edited for Stacked smoker Thanks)
Ear/hearing protection when using grinders and such.
Safety glasses
Goggles.
Face shield.
Leather gloves.
Long sleeve flame retardant shirt.
(Edited for Wreckless and Oz Thanks)
You should always wear long pants and shirts with no frays or loose ends.
Full cover shoes or boots.

Basic tools for welding and fabricating.

Tape measure.
Speed square.
Framing square.
Combination square.
4' straight edge.
Torpedo level.
2' or 4' level.
Various C clamps or welders clamps.
Pipe clamps are handy also.
Pipe wrap around.
Chipping hammer.
Soap stone.
4.5" grinder.
36 grit / 60 grit flop discs.
1/4" grinding wheels.
1.16" cut off wheels.
Twisted wire bead brush.
Twisted wire cup brush.
Regular wire brush.
Welders Magnet, (edited for tazz Thanks)

Cutting equipment.

There are several ways to cut metal.
Oxygen / acetylene.
Plasma cutter.
Abrasive chop saw.
Cold cut chop saw.
Porta band.
Sawzall.
4.5" grinder with cut off wheel.

Welding hoods.

There are a lot of styles of welding hoods.
Fixed shade.
Fixed shade with a flip up shade for grinding.
Automatic hoods.
My advice is to purchase a hood that fits your needs and your budget. Just make
sure the helmet you buy is safety certified.

Welders.

There are a lot of welders on the market. My experience is "You get what you pay for".
Smaller 115vac machine are okay if your are building a cooker with thin metal. But if
you are going to be welding a 3/16" and up cooker you should look into a machine that
is 230vac. Wire feed welders are now days the most common less skill in this technique
makes it great for beginner. Stick welding requires more hand eye coordination and
can be frustrating on thinner metals. Both have their place. You just need to figure
out which one is right for you.

Here are some links that I use for references in pit building.
http://www.chapelsteel.com/weights.html
http://www.regaltanks.co.uk/calculator/
http://www.convertunits.com/from/gallons/to/cubic+inch
http://www.kellypipe.com/pdfs/pipechart.pdf
http://www.kellypipe.com/tools_weight_foot.html
http://www.sheetmetalguy.com/sheet_metal_gauge_chart.htm
http://www.offroaders.com/tech/steel-gauge-thickness.htm
http://www.3m.com/us/mfg_industrial/tools/decimal.html
http://www.webmath.com/dec2fract.html
http://www.sherline.com/lmbook.htm
http://www.rodovens.com/welding_articles/welding_rods_application.htm
http://www.missiongas.com/propanetanks.htm
http://thesmokering.com/forum/viewtopic.php?p=138073
Thank You TuscaloosaQ for this link. Very Happy

http://handymath.com/
Thank You Morgan Feldon for creating the online Pit Calculator. Very Happy

http://www.feldoncentral.com/bbqcalculator.html
Thank You Pete Mazz for this great set of calculators. Very Happy

http://planetcalc.com/search/?tag=3128

Here are some links to some welding videos and other tips that might help.

If anyone has a link to a good welding video let me know and I will add it to this list.
Thank You Beertooth for the link to the Miller pdf on smaw welding.
http://www.millerwelds.com/pdf/guidelines_smaw.pdf
http://www.millerwelds.com/resources/video_library/
http://hobartwelders.com/elearning/
http://www.weldingtipsandtricks.com/index.html
http://www.weldingtipsandtricks.com/auto-darkening-welding-helmets.html
http://www.weldingtipsandtricks.com/stick-welding.html
This coping video was found by rodneymeatsnsweets. It is a fantastic instructional video. Thank You rodneymeatsnsweets. Very Happy

http://www.newmetalworker.com/Howto/copejnts.html
Here is a link to redneck trailers, it is very informative on trailer axle placement and components.Thank You TrailerBuilder for these two links. Very Happy

Thank You for the update -dirt- . Very Happy

http://www.redneck-trailer.com/Portals/4/web_content/files/A.pdf
http://www.redneck-trailer.com/ProductsServices/Products.aspx
Thank You Baldwin BBQ for this link.
http://welding-tv.com/
_________________
Always remember slow and steady wins the race.

Hybrid Cooker

SoEzzy · Posted: Mon Oct 11 10 2:27 am Post subject:

I'd like to thank k.a.m for all his hard work on the backend of this welding section, he remembered a lot of good threads with loads of information useful to the total beginner through to a more experienced welder.

This section is not the last word in welding by any means, but by reading the threads and posts, I hope all those that come here will help add more useful information to this site.

This is not a section for controversy, if you disagree with something that is posted, I ask that you do so in a civil manner, the same as I ask it on any other section of the site, if someone helps you or points you in the 'right' direction, you can thank them, if they steer you wrong you can ignore them, but please don't just flame them!
_________________
Here's a change Robert.

I still work here!

killswitch505 · Posted: Mon Oct 11 10 2:32 am Post subject:

thanks kevin i think this is goin to be a very handy sticky. thanks soezzy for making this happen
_________________
Club Disco

Hell Fire Grill · Posted: Mon Oct 11 10 3:28 am Post subject:

Cool new section guys I been wanting to learn how to weld for a while now. Thanks for all your effort.

BBQMAN · Posted: Mon Oct 11 10 6:56 am Post subject:

Just noticed the new section!

Cool beans K.A.M (and SoEzzy)- great job! Cool

_________________
BBQMAN
"I Turned A Hobby Into A Business".
Providing "IMHO" Since 2005.

Oregon smoker · Posted: Mon Oct 11 10 8:56 am Post subject:

Thanks for the new section. Eventually i will be putting it to use.
Kevin, nice job on putting it all together.

TrailerBuilder · Posted: Mon Oct 11 10 11:07 am Post subject:

Very Nice work on this section. I have welded for quite a few years but it is always nice to listen and learn new or different ways to do the job.

Nice work on the section KAM
_________________
X2 Finished Build
Disco Time
Fire Pit

Wreckless · Posted: Mon Oct 11 10 8:41 pm Post subject:

Well done on the research k.a.m. Great addition. Thanks k.a.m. and SoEzzy!! My first contribution....Long pants without frays. The hip frayed jeans look is cool in public perhaps but is akin to strapping some kindling on yourself for metal fab work
_________________
Backyarder
Smoker Grill
Trailer Rig

k.a.m. · Posted: Tue Oct 12 10 9:25 am Post subject:

SoEzzy, Thank You Sir for allowing us this topic section. Very Happy

Thank You Denny, Very Happy

I hope it helps the forum.

Thank You Hell Fire Grill. Very Happy

Thank You Mike. Very Happy

Thank You Oregon smoker. Very Happy

Thank You TrailerBuilder, Very Happy

I know what you mean I read some of these threads and it does help me refresh on topics that I do not use much. There is always room for learning. Very Happy

Thank You Wreckless, Very Happy

I edited the safety area to include no frays on your pants, Great Idea Thank you. Very Happy

_________________
Always remember slow and steady wins the race.

Hybrid Cooker

cody · Posted: Tue Oct 12 10 11:07 am Post subject:

Cool new section

but you for got no open toe shoes or flip flops or lace up shoes

oh when are you starting on the new build

k.a.m. · Posted: Tue Oct 12 10 7:27 pm Post subject:

Thank You Cody, Very Happy

In the safety first section it is covered as full covered shoes or boots.
My cooker build is on hold till after the first. Smile

_________________
Always remember slow and steady wins the race.

Hybrid Cooker

fatirishman53 · Newbie Joined: 15 Jun 2010 Posts: 92 Location: Wichita, KS

cody · Posted: Wed Oct 13 10 10:40 am Post subject:

oh yea where gloves at all time even it the metal might not look hot it is Embarassed

mrcustomsteel · Posted: Thu Oct 14 10 10:51 am Post subject:

Well done Kevin!
_________________
D. Tillery
Texan transplanted in Billings, MT
www.mrcustomsteel.com

k.a.m. · Posted: Thu Oct 14 10 7:27 pm Post subject:

Thank You D. Very Happy

_________________
Always remember slow and steady wins the race.

Hybrid Cooker

tazz · Joined: 11 Sep 2009 Posts: 21 Location: western MA

Great artical so far, one thing I didn't see for tools is a welders magnet. I have several of the basic styles and they do a great job as acting as a set of extra hands espically when it is not practical to use clamps.

Dan

ChuckieD · BBQ Super Pro Joined: 07 Oct 2009 Posts: 1129

Kevin & SoEzzy,
Cool new section guys! Very Happy

Kevin should cut down my calls to you a bit! Laughing

_________________
SEE YA!
Chuckie D.

Big Green Egg XL
UDS build
The Old Brick Barbecue Project!

k.a.m. · Posted: Fri Oct 15 10 10:59 am Post subject:

Thank You Dan, Very Happy

The magnets are listed now. Smile

Thank You Chuck, Very Happy

Hey I like our calls. Very Happy

You must have some questions to ask. Or we can always talk shop. Very Happy

_________________
Always remember slow and steady wins the race.

Hybrid Cooker

Cat797 · Posted: Fri Oct 15 10 12:49 pm Post subject:

Thanks for the new section guys.....really helpful.

Maybe helpful for newbies, but should note that any exposed skin to the arc is going to get a nice electric suntan Shocked

And, making sure your pantlegs cover the tops of your shoes keeps those weld berries out of your socks!

tazz · Joined: 11 Sep 2009 Posts: 21 Location: western MA

So here's a tip I learned a very long time ago: NEVER EVER CARRY ONE YOU A BUCTANE LIGHTER (BIC, ETC) WHILE WELDING OR CUTTING. Bad things can happen. If you must have a lighter on you, please use a zippo.

Dan