Be-Weldered

This week I decided to break out the arc welder we picked up at Sears Hardware a few weeks ago. I've wanted to learn how to weld for years and 52 Projects is just the thing to get me moving. I've seen it done on TV and in auto repair shops, and it never looked too hard. I knew I would have to learn sooner or later because I have metal sculpture in me waiting to come out and that requires welding. Besides, if that chick from Flashdance can weld, how hard could it be? Well, I found out how hard it could be.

I decided to practice on an old beat up scooter that was in need of repair (or a trash heap). The handle was loose so it seemed like a perfect job for welding.

Arc welding is basically an electric circuit that creates an arc between the surface to be welded and an electrode rod. The arc create by the electric circuit melts the electrode rod and the melted material creates the bond. In theory anyway. The arc is very bright and the welding kit comes with all manner of safety warnings and eye damage hazards. It even comes with a very dark protective mask. Not the cool kind like you see on Monster Garage (you know, the ones that have a head band and flip down over the face when the welder knods his head) but one that requires the user to hold it in one hand. So already I'm working with only one hand. Maybe that's just as well. I wouldn't want to weld my hand to something.

Here's how it looks:



Did I mention it is dark? Very, very dark. Like this-is-what-I-see-when-I-look-through-it dark:




How the hell am I supposed to work blind and with one hand??? The instructions tell me right off that it takes a lot of practice to become proficient at welding so I figure I should be good in about 10 minutes. Well, that was before I became a one handed blind man. The trick is... well, there are a lot of tricks; the right amperage on the welder, the right size and material rod for the application, the right distance of the rod to the material, the right angle, the right motion with the arc, the right speed... What. The. Fuck? I was completely lost.



Maybe if I hold the mask real close....





Maybe if I stand up....


Maybe if I lean over and peak around the mask...


Maybe if I ask a neighbor for help....



He was actually pretty helpful and suggested I try a few things like testing it out on a small piece of metal in case the size or composition of the scooter was part of the problem......



That worked a little better but still not very good. It really is a tricky thing; you have to get the rod close enough to the object to be welded so that the arc is created and the rod melts onto the object. If you get too close the rod sticks to the object. Too far away and no arc. But if you can't see a damn thing it's pretty tough to get that right balance. I eventually traded the blackout mask for dark sunglasses and managed a better arc but could not maintain it long enough to get a good bead on the mating surfaces of metal.



I decided to pack it in when storm clouds rolled in. It had poured down rain earlier on my bike ride and was threatening again. And it did. Not too long after we got everything cleaned up the skies opened and drenched the neighborhood.

I have not given up though. I am going to do some more research on welding techniques and maybe find a class (like I really have time for that). I am also going to look into a better/different mask. I think the ability to see the actual weld would be helpful. Welding will indeed make a return visit to 52 Projects.