I am a new welder, no schooling and no books, just watching videos on the computer, certainly not an experienced welder. I have done a few unimportant projects such as a hot air vent in the bathroom. There is an iron railing on the steps leaving my home. Four of the verticals are one-inch sq. tube which is totally rusted out on the bottom. I have searched for heaver tubes but only found 18 gauge. I need to cut the bottoms off of the railing and replace them. The railing, I’m sure is as old as the house which is about 50 years old. Each time I try to test weld the 18 gauge, I burn thru. I’m using 1/16th E6013 at 30 amps but I still burn through. I have 3/32 E6011 & 3/32 E7014 & E7018AC. my welder (My Amico ARC-160D Welder) will not do AC) I also have 1/8 E6011 which I know will not help. I think that I can increase the thickness of the tubing by laying some weld onside the tube. Am I crazy or will it work and if it will work which is the best of my electrodes to use inside the tubing? I only have to thicken about a half inch near the ends so it should not be too hard.
Trick would be to keep most of the heat on the railing, so instead of a 45 degree into the root of the joint, run your pass at a steeper angle keeping most of the heat on the rail. Would be best to practice on a bunch of coupons first before moving to the real mccoy.
The job is finally complete. I got it all done by thickening a half inch at the end of the tubing. I even did it up into to the old ends so that I could weld the new to the old. Welding the new to the old with all ends thickened was a snap with 1/16th E6013. I'm pretty proud of it even if some of the welds are ugly. With a little black paint they will be beautiful.
