How To Weld Thin Metal Using Flux Core Gasless Welder | Flux Core Welding Tips And Tricks |

The week we are going over how to weld thin metal like exhaust systems and turbo manifolds. The concept is actually fairly simple and you could be welding like a pro in no time. The process starts by getting your welder on the lowest settings and get your metal nice and clean. Butt up the pieces as close as you can to each other and close the gaps as much as possible. Tack weld the part in several places in order to keep the part stable and solid. Tacks should be started on one part of the base metal and then bridged to the second base metal that you are trying to bond. Because flux core wire is harder to get flowing, you'll need to tack all the way around or youll risk overheating the part. Once the part is completely bonded, you should be able to make a second pass right on top if you need to. Practice makes perfect and the only way to start getting better is to start doing more. Good Luck!
How To Weld Thin Metal Using Flux Core Gasless Wire | Flux Core Welding Tips And Tricks
#fluxcore #welding #weldingtips
In today's episode of how to learn flux core welding for beginners, I cut up some pieces of scrap steel to show you guys the drawbacks of welding on rusty dirty metal. The process is not too different from welding on your own with clean metal, but it does take some precautions. Follow along this short video so you can learn what to expect when welding rusty and dirty metals.
The video had to be shot completely 3 times over because I could not get all the info to fit in a tiny video. Flux core welding is relatively cheap and easy to do, plus you don't need anything fancy to do what you need to get done. Today I'll be showing you guys how to set up your welder for welding with flux core. Although getting the hang of your hand control is the biggest issue with bad welds, the rest will fall on setting up the machine settings for flux core as well. Please remember that these machines have to be set up with electrode positive.
#fluxcorewelding #howtoweld #gasslesswelding
his is another long one fellas. Way too many of you guys are asking about this so instead of replying to each of you one at a time I'm just going to link this video for you and hopefully it helps out your flux core welding. I might become a flux core welding channel pretty soon lmao. Basically in the video I show you guys how to take a regular gasless welder and use it to weld upwards or vertical. Once you get the hang of it, its not that hard so as long as you keep trying, it should all work out!
How To Weld Flux Core Vertical Or Upwards For Beginners | Gasless Welding Tips and Tricks |
Several people thought the flux core process was weak and dirty so this video is to basically test to see how well the welding process actually works. Settings are the same as last time and the welder is a vulcan omnipro 220 welder from harbor freight tools. Let me know if there are any other videos you guys want to see about welding and welding accessories.
How Strong Is Flux Core Welding? | Gasless Flux Core Welding For Beginners Tips And Tricks |
Learn how to take your basic welding skills to the next level with 5 easy things your can do to have better performing welds in less than 10 mins. I go through 5 easy ways to weld flux core wire and make it look like gas mig welds. You can take these tips and tricks to better your hand control and finally get the welding results you are looking for. Flux core welding for beginners is the best way to learn how to make clean and concise welds with just a little bit of effort. It only takes a little bit of practice and you will be welding like a pro in no time at all. Tools used in the video are the vulcan 220 welder from harbor freight. Slag hammer from harbor freight. Tig welding gloves from harbor freight and Lincoln flux core welding wire size .030.
Learn Perfect Flux Core Welds In 10 Mins | Gasless Flux Core Welding For Beginners Tips And Tricks |

[@NightWrencher]

If this video was helpful to you, consider donating a few bucks to help me keep the lights on and make more content just like this, THANK YOU! www.givesendgo.com/TheNightwrencher

[@richardnorris9435]

Finally someone who explains how to weld thin wall metal. Your the man! Thanks so much

[@NightWrencher]

Thank you! I really appreciate it!

[@OldJoe212]

Watch Fitzee's Fabrications. He does a lot of bady work with 20-18 ga. I've welded quite a bit on my Jeep thanks to him.

[@Irishjay1025]

Don't do this

[@RandomAuto12]

I’m glad as a non taught welder that when I watch videos like these teaching you that I’m doing things right or at least have the right ideas and directions to make my welds the best. How you explained is exactly how I did my exhaust with flux core. Thanx man

[@NightWrencher]

Thats awesome!

[@BOREDANDWELLBORED]

@@NightWrencher what's the exact amp, dials and the name of the flux used for thin metal? I need to build a exhaust for a generator so it's even thinner than your car exhaust pipe.

[@carlosarthurpetry3674]

​@@BOREDANDWELLBOREDif it is even thinner, you might be better off with oxy acetylene and soldering.

[@LynMoore-cj8we]

​@@BOREDANDWELLBORED❤😂😮

[@codures]

Kinda like you mate. Did some body work on my car. The thinnest plate was like 1/6... Put the welding in 13v/30-40A and minimum inductance. I tacked the corners, run a spot like on both edges to get'em closer together (I had ~1/10 missing) and then started the same spot weld technique but on the puddle in the middle and doing it much faster. Maybe I'll help someone.

[@JerameyDonathan]

This honestly made so much sense to me. I’ve been experiencing most of the issues you talked about here and I figured a few of these issues out on my own the extra input from you deff helped me thanks man.

[@NightWrencher]

Thats awesome man, I hope you get it

[@elgalloclaudio4780]

What brand mig welder do u use ?

[@reloda]

Very helpful video, I have a cheap (£100) gassless mig welder and I've been attempting to weld some thin metal pipes and blowing holes straight through, this vid clearly explains the correct procedure and concept

[@jamesward5721]

Key when welding exhausts is to weld onto weld. I.E stick a weld onto the old material both sides, not trying to join anything - then join your welds to each other. Once you get even a tiny bit joined - no matter how big the gap is - keep welding onto your weld, ignore the base metal. Weld onto weld. Using a long C as your weld pattern works great - just keep laying one C onto the next C, working around the whole pipe. The benefit of using big C's is when you're done, it looks real pretty too. :-) Like stacking dimes.

[@NightWrencher]

Thats what I do too. welding in a C is uncommon in other welding processes but for flux core it works great

[@jamesward5721]

@@NightWrencher Flux core is also waaay better for "spot welds" - I.E plug welds to join panels. More especially so if you are using weld-through primer. Gas mig will sulk & spit, flux core will weld ahead & with better penetration. Filling big voids is also fast & easy with flux, plus it cares a lot less about "perfect" metal preparation.

[@douglasgallardojr4759]

You have to clean the slag off between each layer. The tack method is a good idea, but clean it before your next pass.

[@lucasblizzard7261]

That depends on the consumables used tbh. What he did was a "stitch weld" and you see that on auto body metals a lot. Cleaning slag is more important for thicker metal. If you have a wire that puts out next to no slag, like some do, and if your weld pool isn't getting too cold before the next stitch, then you won't see slag traps as much or at all

[@bobs12andahalf2]

I just got started with flux core, 9+ times out of 10 I find the slag flakes off spontaneously on cooling, on rare occasions some gets a bit of purchase but welding on top of it seems to just melt it and add it to the pool. No inclusions yet. I'm absolutely hooked now, never suspected flux core would be so much fun.

[@idabomb00]

@@lucasblizzard7261 says right in the title flux core, one of it's characteristics is leaving a layer of slag. Regardless of what welding procedure you are using you should always clean the weld between passes.

[@lucasblizzard7261]

@@idabomb00 I'm a welder

[@damiropadobarglumskiperiod505]

One question to ya all i have 0.30 wire and i need it fo car bodie panels 1 mm .will i ger better results if i buy thiner wire 0.30 is 0.8 mm and i can put thinner wire 0.6 mm

[@r.rejinbabur.rejinbabu1311]

You've got a great teacher.He patiently and gracefully teaches you everything from fabrication to welding.All the teachers who taught us while we were studying were very strict with us.Watching this video reminds our study time AWESOME

[@eugene5438]

Always appreciate your welding videos. Great tips, thank you.

[@NightWrencher]

Thank you! Have a new one coming up soon!

[@tomhenschel1104]

Some people are just born to be great teachers. You’re one of them.

[@NightWrencher]

Thanks man, the means a lot! 👍

[@vincentdelucia8078]

My man, thank you, finally a thorough explanation on welding thin metal. Whether it be speed and size etc. Thank you!! 💯

[@NightWrencher]

Thank you! I appreciate it!

[@markdishmon681]

Awesome information brother. Soaking up all the information you give us. Nothing but respect brother.

[@NightWrencher]

Thank you sir! I really appreciate it!

[@Mekaleeto_Worldwide]

I'm self taught, which means I'm horrible with thin wall, until I watched this.. I was beveling and blowing through nonstop, watched this and boom, my blow through problem solved.. thanks man.

[@NightWrencher]

Thats awesome! I'm happy its working for you!

[@bigmotter001]

A lot of great tips NW. I haven't welded any exhausts yet but will definitely use these tips when needed. Thanks for sharing and take care!

[@NightWrencher]

Thank you! Always a pleasure 👍

[@thisfool90]

If you've never done it before it is tough. So easy to blow through. This video has enlightened me, after having made all of the mistakes

[@kerrygibbs8198]

You did a great job giving information. Your tips will help me improve. Thank You!!

[@NightWrencher]

Thank you! I hope it helps!

[@ahmedrobles2834]

Very well explained. As an amateur welder I have come to the same conclusions as explained in this video. All the tips are important.

[@NightWrencher]

Thank you! I appreciate it!

[@timothysexton6800]

Your videos on thin metal wielding are very helpful. We all think you for your presentations

[@NightWrencher]

I appreciate it! You're welcome!

[@huntintrailmetals9343]

Thanks for this tip I am a beginner welder and self taught welder so this tip really helps me!

[@NightWrencher]

Good luck man! All it takes is practice!

[@MMORPG87]

I legit just sat down after putting in some practice and this vid popped up soon as i opened youtube. This helpbreak the fog I my head why i was having a hard time. I was doing great on think metal but was confused when trying on sone old pipe now i get it. Thank you

[@naradloff]

I just started welding. I'm currently restoring a 1973 Jaguar XJ12 and the exhaust was TOAST. Your instructional videos have helped me tremendously.

[@NightWrencher]

Thats awesome man! I hope your restoration goes well!

[@qmoonwalker3847]

Great video series! I know I'll be referencing back to many of them.

[@NightWrencher]

I really appreciate it! More to come soon!

[@Andrew_Fernie]

The best budget friendly, practical, just get it done coz it ain't for Instagram, beginners mig welding video I've seen. Thanks !

[@NightWrencher]

Thats what flux core is for!

[@ericmurray3705]

I really like the idea of going right over the weld to really pull it all together! Thanks for the video!

[@marka1712]

Awesome video. Thanks for the tips. Beginner and looking for all the info I can get to help along the way

[@NightWrencher]

Thanks you! I hope it helps you out!

[@daveysprocket3946]

Very informative. Thanks!

[@awalk5177]

Excellent video. This information is exactly what I was looking for regarding flux core. Thank you.

[@NightWrencher]

Thank you! I hope it helps!

[@mattwhitt3212]

@@NightWrencher ipĺp

[@awalk5177]

@@NightWrencher More than you can imagine. I just found my Land Rover exhaust has come apart at a flange. The metal looks good, it just looks like the manufacturer was very shy when welding on the flange and the two have parted company. I think I will mark up the alignment, take the pipe off and redo the flange weld. If it works the system should last me a few more years as the pipes all look fine.

[@NightWrencher]

I've had to the same thing on rusty subaru exhaust and as long as you go wide, you should be ok. The broken ends will be very thin

[@awalk5177]

@@NightWrencher Thanks for the advice. I will double check, but it doesnt look broken at first look, it seems to have just pulled out of the flange. Maybe it was only tacked. If I have to buy a new mid pipe its not a big issue. Thanks again.

[@laguaguacolectivo6703]

Great video so much to learn i am new to welding and this makes so much sense

[@robburke5577]

After 20 videos, I finally found what I was after. Great video!

[@NightWrencher]

Thanks man, I hope it helps!

[@crawford323]

I expect this is not the only bit of wisdom this young man has to offer. Darn right I’ll subscribe

[@NightWrencher]

Thank you! I really appreciate it!

[@dans_Learning_Curve]

Thank you for this video! Something I've been struggling with. Will attempt to improve!

[@NightWrencher]

Good luck! I hope it helps!

[@richarddiaz8248]

Did not know I can ground the cable to the angle iron thank you for your knowledge and experience

[@NightWrencher]

As long as you have a clean ground to a metal surface that touches your metal, you can have the ground anywhere!

[@octavio152]

Picked up a welder and starting practicing, thanks for the video

[@jameswallace7351]

Great video you just helped me a lot on a little trouble I've had before thanks

[@NightWrencher]

Thanks man, hope it works out!

[@scotthansen4073]

I can't thank you enough for sharing this video. Great tips !!! This is a video to save !!! Keep up the great videos... Please !!!

[@NightWrencher]

Thanks Scott! I appreciate it!

[@zeropointzero]

Awesome video! This is the way. I've been welding exhaust with flux core for years. It's not show quality, but I've never had one come back, and my welds outlast the parts welded together.

[@mikeaiken7424]

Really good video bro just what I needed when I needed it. Thanks again

[@NightWrencher]

Thank you! I hope it helps you out!

[@robertjohnson5227]

Great video and it's perfect as I have to fix my exhaust tomorrow Thanks for the tips

[@NightWrencher]

Hope it helps!

[@kelvinsparks4651]

Well done, you explained the procedure very well.

[@erikg.4217]

Thank you! Excellent video!

[@davehoward2791]

Now that there is some very useful information. Thanks! 😀

[@NightWrencher]

Thank you! Much appreciated!

[@centariprime9959]

Good video. We'll presented. Thank you.

[@DreamDrivenMediax2]

Super descriptive video, appreciate it man! Just bought my own flux core welder that I’m going to be learning on

[@NightWrencher]

Good luck! Its all just practice!

[@DreamDrivenMediax2]

@@NightWrencher 💪🏼💯

[@RealSuburbanCowboy]

I love this kind of video. Super helpful and informative. THANK YOU!

[@NightWrencher]

I really appreciate it! Thank you!

[@ronaldsmith2043]

Extremely helpful Great way to explain ty

[@joeysimmons2779]

Thank you been searching and searching so rad thank you again

[@NightWrencher]

Hope it helps!

[@NitrousFTW871]

Great teacher!....just subscribed for more tips and tricks

[@NightWrencher]

Thank you! Theres more on the way for sure!

[@davydacounsellor]

100% well done and well explained.

[@samTollefson]

Thank you for that advice!

[@NightWrencher]

I hope it helps!

[@dandeangeli9860]

Very helpful clear explanation. Thanks for making this video.

[@NightWrencher]

Thank you! I hope it helped you!

[@fireboyisme]

Thanks for this great video.

[@NightWrencher]

Thank you! I appreciate it!

[@mnhoss2100]

This was helpful information thank you sir.

[@NightWrencher]

Much appreciated!

[@northerntranquility1614]

Great tips excellent video thanks

[@NightWrencher]

Thank you! I hope it helps!

[@ryandubia]

Just learning how to weld and my first job is exhaust on my project truck. I've been practicing on the old exhaust that I cut off and I've been burning through it and doing basically everything you said would happen. This video was a huge help. I can't wait to get home and try again.. Thanks!

[@josephleister9198]

Excellent video...thanks

[@NightWrencher]

Thank you! I appreciate it!

[@rogue3524]

Verry good tips! Thank You for sharing. 👍

[@NightWrencher]

There are more videos to come so I hope you enjoy!

[@rockcrusher4636]

Excellent, thank you for sharing. Cheers.

[@NightWrencher]

Good luck!

[@michaelmccorkle6279]

I learned a few things here. Thanks.

[@NightWrencher]

I hope it helps!

[@dandeangeli9860]

super helpful guidance for how to weld thin materials...thanks NWrencher

[@NightWrencher]

I appreciate it!

[@MasterofTongs]

Notice the wait he takes between each weld to when filling the gap? In my (year of) experience, that's because if you run for too long on really thin metals it'll melt through. Fight your stick welding urges until you've put in the root, then go back over it. It's just going to have to be ugly as sin the first time through.

[@NightWrencher]

Exactly right!

[@lostinadream1866]

great video!

[@cozmo989]

Ive watched heaps of these vids on youtube, this is the easiest to understand.

[@NightWrencher]

Thank you! Hope it helps!

[@vrm86gt]

Thanks, going to check out the flux core playlist!

[@NightWrencher]

Awesome! Hope it works out for you!

[@vrm86gt]

@@NightWrencher Thanks, I need all the welding tips and help I can get!

[@richardduvall6512]

Good tips thanks for sharing

[@NightWrencher]

much appreciated!

[@jimmysegovia2688]

thank you, man! you are an excellent welder I need to learn A LITTLE.

[@NightWrencher]

Practice makes perfect 👍

[@ATinyPillow]

Just use a coat hanger as a filler rod as you weld the seam with your wire feed welder. Lay the coat hanger along the seam and strike your arc on the coat hanger instead of on the thinned exhaust pipe. Works like a charm when welding thin metal, you ought to give it a try. .

[@NightWrencher]

Thats really interesting! I'll try it!

[@ATinyPillow]

@@NightWrencher : Had my own bodyshop for years prior to retirement, works like a charm. .

[@bryanbisimotopinas345]

@The globe is DEAD how about using flux core wire? I have lots lying around that are left when changing spools.

[@ATinyPillow]

@@bryanbisimotopinas345 : I know that well, lots of useless flux core 6’ long. The coat hanger is larger diameter, the arc blows the flux core wire away like thin metal, too small. It’s a shame because it would be a great way of using up those worthless scraps of flux core. .

[@msk3905]

@@ATinyPillow so what if you wrap several pieces of flux making it larger diameter?

[@shafeeemamdee6638]

Nice Video!!

[@justinsmith847]

This is great thanks for all the info

[@NightWrencher]

I hope it helps!

[@jasonsmith3573]

good stuff, just what I was lookin for

[@NightWrencher]

Thank you! Hope it helps!

[@WimpnitTv]

Great video for beginners keep it up

[@NightWrencher]

I really appreciate it!

[@joshuagarvey9362]

This is A great video.Thanks so much.

[@NightWrencher]

Thank you! I hope it helps you out!

[@notimportant8120]

I’ve found that stick out length can greatly help with bridging less than ideal gaps on thinner gauge steel on gasless wire

[@NightWrencher]

There's a lot of little tricks, maybe I'll do a video on it on of these days.

[@ussweeneyd]

Great tips! Thanks.

[@NightWrencher]

Hope it helps you!

[@marktomlin5484]

Thx for the lesson .

[@NightWrencher]

Hope it helps!

[@kmlumd44]

Seems like good input. I love how with KZbin i can watch multiple videos and accumulate the highlights of each one to approach something new with confidence like welding

[@NightWrencher]

Exactly right!

[@kmlumd44]

@@NightWrencher did u ever do heat shields? I was thinking to tack hex head machined screws like cookies to a sheet metal sheet and cutting squares to tack them to the car body. Any tips on tacking to the body? Where should i ground. I got 2 shields to do with the exhaust repair

[@NightWrencher]

That can work, you can ground on any clean piece of metal on the body but you need to make sure the battery is disconnected and any computer is unhooked from the ground to prevent damage

[@kmlumd44]

@@NightWrencher okay i gotta do the exhaust this week so ill do the shields. I honestly wouldnt of disconnected the battery or the ecu but i will now. Makes sense to play safe. Thanks for liking my comment so i could ask this

[@mancavecustoms13]

Real good practical advice my guy. Will go back to garage and use it right away. Todays practice welds got me real depressed haha

[@dhandylab]

Finally some real world welding help. Enough right on the money advice for a common sense person to do the job. First time using a yard sale mig and every single video I watched just made me panic. there was no way this was going to work. Every bad thing you described might happen did on my first try. Did what you said without cleaning anything once I started. Then hit it with the grinder once it was all put together. After that it was easy to make it all pretty just like the other videos show you. Thanks

[@NightWrencher]

Glad it helped!

[@The_Impulse]

I built both turbo manifolds for my projects with a Lincoln flux core machine. The second obviously turned out better cause the learning is the fun part.

[@NightWrencher]

I know exactly what you mean XD

[@coalroller9482]

Excellent thank you needed that help

[@NightWrencher]

Thank you! I hope it works out!

[@aaronward4319]

Thank you sir, verry helpfull!!!!!!

[@s.o.s.exploration2412]

Makes perfect sense. Thx

[@NightWrencher]

Thank you! Hope it helps!

[@eastcoastken]

This was very helpful. I'm about to weld a test pipe together using a new exhaust piece on some old flanges that I will sand blast.

[@jimfeaster4837]

Great lesson...

[@NightWrencher]

Thank you sir! I appreciate it!

[@ROGUESQUADGARAGE]

Great info, thanks

[@NightWrencher]

Hope it helps!

[@a_w_bukhari7579]

Good info 👍🏼

[@NightWrencher]

Thank you! I hope it helps!

[@infamousnova]

Alot of good info

[@NightWrencher]

Thanks man, one step closer 👍

[@whatyousaidbud]

Thank you for sharing your time, I will sub immediately!

[@NightWrencher]

Thank you! There are more videos like this coming!

[@coachLou12]

This is very helpful. Great videos. I’m new to welding. Have you any videos on cutting and installing a patch panel on the floor of your pickup?

[@NightWrencher]

Not really because my floors are not rusty 😅 but I will when I trim the back of my truck bed 👍

[@GS-kb1vy]

Good tips thank bro

[@Goomer]

Good advice thanks

[@NightWrencher]

Much appreciated! Thank you!

[@michaelstewart2495]

Thank you...that is what i needed to hear. I am a bit of a challenged welder,and i am building a drift trike with some friends and i was turning it into swiss cheese...lol...so thank youbagain

[@NightWrencher]

Hope it works out!

[@lastcent5140]

Great information, helped heaps to get a nice weld. One thing with the video, have the program treat the audio as a mono track and it'll fix the odd panning issue. Thanks, hope to see more :)

[@NightWrencher]

Thats a great tip! Thank you!

[@anthonymarino4260]

thanks for sharing

[@NightWrencher]

Thanks man, I appreciate it

[@luisbatista1103]

Great content

[@NightWrencher]

I appreciate it 👍

[@jvazquez53]

Nice tip!

[@NightWrencher]

Thank you! I hope it helps!

[@rayzor285]

Haven't heard anyone recommend this yet. I've been having issues blowing through .065 tubing so I'm going to try this!

[@hankclingingsmith8707]

Good VIDEO

[@NightWrencher]

Thank you! I appreciate it!

[@outdoorzone]

Good tips! Another method to welding super thin material is tack welding it 100% with all tacks over lapping 50% or run small beads 1 at a time then cool with air and continue on until joint filled!

[@NightWrencher]

Exactly! Very tedious but it works!

[@jeremyoshea7941]

Your a great listener, and/or someone was a great teacher! Great video very educational! Thank you for your time! I learned more here then I did in my 8th grade small engine repair class… lol you know what I mean.

[@NightWrencher]

Thank you! That means a lot! I try to explain like I like to learn. I assume the person listening doesn't know anything so I try to explain as clearly as I can and cut out all the real technical stuff because its not useful to them at this level.

[@williebateman3613]

Thanks welder brother 💥💪🏾

[@NightWrencher]

👊 hope it helps!

[@gwarbong]

very useful information. will help a lot of people. you guy's gotta go ahead and actually essentially take it easy with the KZbin lingo though. at least I didn't hear smash the like button, or hit that bell, or the link is in the description. but anyway, thanks for uploading and helping others, it takes time and allot of extra effort. Great tips, all on point.

[@NightWrencher]

It takes me an hour per minute of video posted so it is indeed a lot of work! Thank you!