Can I repair bush hog sheet metal with stick welder?

[BeezFun]

I've got an old ford bush hog, the sheet metal is rusted through around edges but gearbox and structure is in good shape, so I'd like to try to repair it. I'll be cutting out and replacing the 20ga sheet metal with patches. Then I have to weld the new 20ga patch material to angles and brackets that range from 1/8" to 3/16" thick. So the big problem is welding thin material (20ga) to thicker material (1/4"-3/16"). I'm a pretty good stick welder, a really good gas welder, but don't do mig, and I'm trying to decide if this is doable. I'd probably go through a tank of gas trying to get this thing hot enough, and it would be tough to avoid burn through, so that probably won't work. Is it possible to stick weld these two materials? I generally use 1/8" 6010 to tack everything, then 1/8" 7018 to run the bead on thicker material. What would I use for this if it's doable?
tnx

 

[k0ua]

I've got an old ford bush hog, the sheet metal is rusted through around edges but gearbox and structure is in good shape, so I'd like to try to repair it. I'll be cutting out and replacing the 20ga sheet metal with patches. Then I have to weld the new 20ga patch material to angles and brackets that range from 1/8" to 3/16" thick. So the big problem is welding thin material (20ga) to thicker material (1/4"-3/16"). I'm a pretty good stick welder, a really good gas welder, but don't do mig, and I'm trying to decide if this is doable. I'd probably go through a tank of gas trying to get this thing hot enough, and it would be tough to avoid burn through, so that probably won't work. Is it possible to stick weld these two materials? I generally use 1/8" 6010 to tack everything, then 1/8" 7018 to run the bead on thicker material. What would I use for this if it's doable?
tnx

It will be difficult, but you could try some 1/16 inch sticks of 6013 (you can get them at lowes) to try and glue that 20 gauge steel onto the thicker stuff. Try about 35 to 40 amps DC. I would TIG it with what I have. If your stick welder is DC you can get set up for scratch start TIG for a bout $100 plus rental of an argon bottle. I believe the sticks I mentioned will do it, and I have welded some pretty thin sheetmetal with them, but I don't think I have ever welded 20 gauge. I would definitely reach for the TIG torch if I was faced with this as I don't have a MIG either.. As you know MIG would be the fastest and easiest.

 

[Mendonsy]

You might be better off to make the patches out of something a bit heavier just to make it easier to weld. 20 ga. is awfully light for anything but a TIG. 14 ga. would be a whole lot easier to work with but isn't as flexible.

 

[k0ua]

You might be better off to make the patches out of something a bit heavier just to make it easier to weld. 20 ga. is awfully light for anything but a TIG. 14 ga. would be a whole lot easier to work with but isn't as flexible.

I was wondering about that too. Isn't the metal on a rotary cutter normally a lot thicker than 20 gauge? I would worry about blowing rocks thru it.

 

[Shield Arc]

My brush hog is 12-GA. I'd grab the Tig welder for 20-GA. Even though I worked out of the Sheet Metal Union for 3-years, I don't think I've ever welded 20-GA.

 

[k0ua]

My brush hog is 12-GA. I'd grab the Tig welder for 20-GA. Even though I worked out of the Sheet Metal Union for 3-years, I don't think I've ever welded 20-GA.

I agree about the TIG, but do you think it could be welded with some of those 1/16 sticks of 6013?. 6013 is a low penetrator to begin with. I don't think I have stick welded anything quite that thin, have you?

 

[jack707]

turn the heat down use 3/32 rod or 1/16 if you can find them.

 

[newbury]

I used 10 gauge to patch a hole in my brush hog.
I know it looks like bird poo, but it held after I patched a couple of holes.

I gave it the hammer test, then used it for an hour or so.

But that was my first weld w/ my $265 PA 300, I had to run it at about 28 amps w/ 1/16 rod and I still blew holes.

A mig would have been more appropriate.

/edit - I could not imagine hogging with a bush hog with 20 gauge metal on the deck, my rocks would fly right through it.

 

[Shield Arc]

do you think it could be welded with some of those 1/16 sticks of 6013?

I've only heard of them, never even seen them.
If I just had to do it with SMAW. I would tack every 1/2 inch or so. Weld from one tack to the next one in line. Move to another location, and do the same thing. I would also try to clamp a copper or aluminum plate under the weld area as a heat sink.

 

[yomax4]

Lincoln has Fleet Weld 37 in 1/16 and MG has a nice one called "easy strike". Run great on 40-60 amps. I agree with the 12ga patch a bit larger than the owie. should be an easy fix.

 

[big bubba]

though i worked as a welder in my youth, i'm a long way from a pro. like the idea of going heavier gauge for the patch. of course mig comes to mind. if stick, go w/rods recommended above, reverse polarity, make say 1-2" intermittent beads, then either come back to weld, or use high quality sealant between. (rod technique & angle, not lingering in puddle for long but for adequate penetration) can also keep the heat from blowing through.... clean sand/grind prep is what it's all about too. let us know how it goes

 

[ruffdog]

I never used small 6013 so I'll have to get some to tinker with. The local store has Hobart 1/16 and 5/64 on sale too.

 

[big bubba]

I never used small 6013 so I'll have to get some to tinker with. The local store has Hobart 1/16 and 5/64 on sale too.

fairly close to the 6011 standby, definitely not a drag rod. might have more iron in the flux, but may stand corrected on that. betcha you can do it.

 

[oldnslo]

the main thing I have found on thin material is do your very best to get it nice and clean and have tight joints. Any gaps allow burn through much easier and 6013 doesn't burn through rust & dirt real well either.

I have welded walk behind snow blower housings with 6013 and my old Lincoln 225 buzz box. Like Shiel arc suggested tack it every 1/2 inch or so and skip weld helps dissipate the heat also.

 

[BeezFun]

Thanks for all the input, I must be wrong about the gauge of the deck metal, I was looking at the area where it's rusted pretty bad and it seems really thin, so I was just guessing. But I looked online and it seems most machines of this class have anywhere from 10-14ga decking. This cutter is from the 60's, when men were men and steel was thick.
I've got a Lincoln tombstone AC/DC, so I think I'll try electrode negative with both 3/32" 6013 and 3/32" 7018. I find 7018 much easier to drag than 6013, but haven't used either for anything this thin. Maybe once I cut out the bad areas there won't be enough left to bother patching.

 

[k0ua]

I've only heard of them, never even seen them.
If I just had to do it with SMAW. I would tack every 1/2 inch or so. Weld from one tack to the next one in line. Move to another location, and do the same thing. I would also try to clamp a copper or aluminum plate under the weld area as a heat sink.

I have burnt a few packages of them. You can weld pretty thin stuff with them, but I don't know about 20 gauge..

 

[k0ua]

Thanks for all the input, I must be wrong about the gauge of the deck metal, I was looking at the area where it's rusted pretty bad and it seems really thin, so I was just guessing. But I looked online and it seems most machines of this class have anywhere from 10-14ga decking. This cutter is from the 60's, when men were men and steel was thick.
I've got a Lincoln tombstone AC/DC, so I think I'll try electrode negative with both 3/32" 6013 and 3/32" 7018. I find 7018 much easier to drag than 6013, but haven't used either for anything this thin. Maybe once I cut out the bad areas there won't be enough left to bother patching.

OK, now we are talking, I am sure that your metal is way thicker than 20 gauge Yeah get the 3/32 7018 after it and go..

 

[newbury]

If you've got many holes it might be worth picking up a pound of 1/16 Lincoln rods from Lowes if you can't find them elsewhere.

 

[big bubba]

If you've got many holes it might be worth picking up a pound of 1/16 Lincoln rods from Lowes if you can't find them elsewhere.

taking that to a another level (esp w/large rust voids on examples other than yours) you could always cover the entire deck w/medium gauge material. actually, on my own larger HD hog, they have 2 layers on the top deck, one for abuse, the other for appearance. not in any way recommending that, just that options vary. my take would be going the simplest route possible to achieve the job.....you have the advantage knowing the fix is not structural. best regards

 

[PILOON]

Would you believe that I have welded 6013 with an industrial 24 volt 25 amp transformer? 1/16 and 3/32 works.

The transformer is a Hammond generally used on heavy production to operate relays etc.
Striking an ark is challenging but darn good practice, also you get to reset breakers often (sticky rod) .

While I never bothered to check out penetration, things tended to stay glued.