Will .030" Fluxcore Work for Minor Rust Repair?

[Dan in Pasadena]

Hi guys,
If you've been following my main thread you know I'm getting ready to install door weather stripping but encountered a few very small holes: 1/8" to 1/4" on my door bottoms I need to repair first.

Yes, I KNOW .023 with "MIG Gas" (ArCo2) would be best.

I fully intend to do that in the future but I have no bottle (yet) with my Hobart Handler 140 so it will cost $189 to buy/fill the first time. I'd like to get away cheaper IF I can make it work for these tiny holes. Yes, I know to use the lowest possible heat setting and a series of tiny tack welds. I know to use a copper backer (Harbor Freight cheapo or flattened copper pipe) Can this .030" wire work?

[broey]

yeah it will work, just more grinding and smoothing than with gas. but you should be fine

[55dude]

Bunch more work! Dial it in first on some other old sheetmetal first and then decide.
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[Kim57]

What they both said. I think your biggest problem will be if the surrounding metal is real thin and you just blow the hole bigger. Other than that you should be fine.
Kim

[Dan in Pasadena]

Thanks guys.

I've got a spare door that's a POS I'll use to practice on. Then I'll weld my doors welding from the INSIDE - because the prior owner cut not one, but TWO giant speaker holes each of them! That'll work in my favor for this purpose, then I'll use donor metal from the spare door to repair the speaker holes (for that I'll use .023 & gas) - unless the fluxcore works better than I think, because I'm a cheap bastard and I've been spending like a drunken sailor on chrome!

PS: if it DOES blow holes I'll own up to it, bite the bullet and go get the gas.

[Russell Ashley]

Dan, IMO, If you are ever going to buy the tank and .23 wire, go ahead and do it now before you make the holes bigger with that shielded wire. It's not going to cost any more to buy it now and it will probably save you some aggravation. Shielded wire is fine for some things but not for what you are going to do.

[dubie]

I just welded in a couple patched with .35 flux core. The key is to get the heat dialled it properly. On my little 110V Lincoln I have the heat on the 2nd lowest setting and a wire speed of 2 and as long as you work the metal properly, it'll come out fine, just be patient. I only used flux core because I ran out of gas and was in a pinch. I usually run a .26 wire with an argon mix gas. ANYONE can weld with that combo.

[_Ogre]

I weld a lot with fluxcore , yes it will work but you still have to cut it back to solid metal
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[Denee007]

Well, my experience is I had a flux mig from HF~ I used it on my 67 Mustang for floor pans, and things, but the welds were not very pretty, puts out a great deal of fumes/smoke(deadly), and you need adequate ventilation, I believe more so than with a gas type. I talked Gary into letting me purchase a mig with gas from Northern Tools~ and I weld great now(night and day kind of welding) ! If you're going to do more welding in the near future (I'm sure you will)~ make the purchase and get something you'll be proud of and not cuss out! Without the proper tools you'll be greatly slowed down! I also found using the large spool of wire vs the small spools doesn't get tangled as much, well, the large roll Ive never had a problem with. I also long since did away with the little oxy/acetylene bottles and bought the large bottles for my cutting needs. I actually went a little crazy on the machines!

The one on the far right is for my lighter welding, the larger used mig on the left I have the larger wire in for heavy metal. The Chinese thing in the middle= big mistake!

[Dan in Pasadena]

Oh man, you guys (& ladies) are appealing to my "do-it-right-the-first-time" shame....and I'm a construction Quality professional. DOH!

Lol. Ok, ok, I'll head over to Airgas today and bite the bullet. I suppose (well, I really KNOW) you're all right.
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[Denee007]

Good for you Dan!. Be sure to post a pic of your new toy!

Originally Posted by Dan in Pasadena

Oh man, you guys (& ladies) are appealing to my "do-it-right-the-first-time" shame....and I'm a construction Quality professional. DOH!

Lol. Ok, ok, I'll head over to Airgas today and bite the bullet. I suppose (well, I really KNOW) you're all right.
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[mr48chev]

There's the monthly bottle rental fee but some welding supplies have rental bottles that you pay about 10 bucks a month rent on and just buy the gas that goes in them. In the long run it isn't the prudent thing to do but it does help with not having to make the big cash outlay at one time.

I lucked out and found my bottle that was almost full at the time on craigslist for 50.00. I didn't think my pickup could get across town that fast. It's about 30 bucks to fill/exchange it at the welder supply.

[Kabwe]

Man why don't you just do it the right way and stop all this bull crap.lol (sorry but you know me and I had to.lol)

Dan get you some gas and some .23 wire and you will be much happier with the results.

[Dan in Pasadena]

YEEEOOOOW!! I'm bleeding from the wallet.

I just left Airgas and it cost me $267!! for a new 60 cu. ft. bottle, package of 10 ea.
stinger tips and a small roll of .023" wire.

This BETTER make me into the "Michaelangelo of MIG welding", ha ha!

[Dan in Pasadena]

Originally Posted by Kabwe

Man why don't you just do it the right way and stop all this bull crap.lol (sorry but you know me and I had to.lol)

Dan get you some gas and some .23 wire and you will be much happier with the results.

Missed your post while writing my own. (Can I come to your place for dinner this MONTH!! ha ha).

Yeah, you're right. Instead of dicking around with chrome tailgate letters on my spray bombed old wreck I should have spent the cash on the right tools....so I did!

Now comes repairing these doors, the big speaker holes, the kick panel holes...and then? I'll be calling you Bam about my roof. I have a BAAD feeling I may have to do a full replacement like you did. (Gulp), I'm hoping I can cut some metal out of the gutter to SEE how bad the rust is in there but if I find what I'm afraid of?....I'll be hiring you!

[Kabwe]

Airgas is a rip off.

Find a mom and pop welding supply and the price will be better. I bought a bottle on ebay way cheaper. What size are you thinking about? I just saw a 80 on ebay for 187 and a 40 for 120 free shipping.

[Dan in Pasadena]

Too late, the cash is gone.

The kid there told me if I found an Argon or Co2 bottle he'd swap it out and I'd only pay for the gas and $12 for a new hydrotest IF it was out of date. I did a quick CL search on my phone and found a full Ar/Co2 bottle with regulator (but I already have one) for $200 out in the Inland Empire. Too far to be worth it. So I just swalloed hard and took it.

I tell you what? If I can't afford to eat this month I'll come for a visit. If you can't afford to next month you can come to my place for beans and rice! lol.

But seriously, I've actually been looking for a used bottle for awhile. Oh well, I'm fine.
I don't much like paying tip-top retail but it sounds like I did...this once. Now I own the bottle and can fill up other places for a lot less. How long in ordinary DIY use (no, not like you use it) can I expect to get out of a bottle this size?

[Dan in Pasadena]

Stupid Duplicate Post #1

[Dan in Pasadena]

Duplicate #2

[Kabwe]

Originally Posted by Dan in Pasadena

I don't much like paying tip-top retail but it sounds like I did...this once. size?

I just call that a "it is what it is" moment. It is what it is so time to move on. I use to go to airgas also until I found a mom and pop welding supply near me. No need to worry about all the times I was over charged. I can't go back and change that.

You know the old saying "fool me once shame on you, fool me twice shame on me".

[Denee007]

Don't look back now! Now go forward and practice and do good work. More than likely you'll be going back to this place for supplies and hopefully they'll know you by name soon; )
Dne'
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[Dan in Pasadena]

Thanks Bam. At least now I know you won't be rolling your eyes about my welds AND my lack of sense, ha ha.

I hadn't planned to make the investment (As the thread title shows) but when you, D'ne, Russell and Mr48 all basically told me to quit fooling around I figured you must be right cause I admire all the work you guys do.

Now, headed home to start prepping. Photos coming with results - be kind folks, be kind.
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[Denee007]

Again congratulations Dan! Mig welders are so neat! As usual, there's a learning curve~
oh, what kind of welding helmet did you get? or do you have?
I bought an auto darkening from Northern Tools and it works very well! I almost bought a really nice one a few months back, but I just couldn't bring myself to give the welding store 250 bucks~ When the one I have really is just fine I have a regular non auto darkening, but I mainly use it when we have an eclipse of the Sun! lol

[Clarance J]

Yeah Dan, those welders can be a lot of trouble. First you start off with just a little job. You know, those little holes in your doors. Next thing you know you want to do those pesky cab corners and then hinge pockets. Pretty soon you'll be thinking that front clip won't be that bad. Then its on from there, welding up that metal lawn chair, bumper brackets, things that your friends bring over. No telling where it will go from there. Just keep sending those pictures.

[Dan in Pasadena]

Yeah, I'm familiar with welding being a slippery slope. I bought my Hobart lightly used from an acquaintance on GarageJournal. He was stepping up to a 220v model so he kept the bottle. I knew I wanted to do mainly sheet metal repair, though I've already done more. I just did it with flux core.

I've got a Harbor Freight auto darkening helmet (insert GASP and "well, if you don't care about your eyes" comments here, lol). I've had zero problem with it and I can see well. Of course I've never had a better one so I have nothing to compare to!
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