So, if you’re looking to declutter your entryway or want to showcase your welding skills, grab your tools and let’s get started.

Project Overview

This tutorial project aims to guide beginners in welding by creating a functional and stylish coat rack using mild steel. The tutorial covers the basics of MIG welding, the necessary equipment, and tips and techniques for welding mild steel.

By following the step-by-step instructions, participants will learn how to create strong and durable joints and how to shape and finish the steel to create a sleek and attractive coat rack for their home or workspace. Whether a DIY enthusiast, hobbyist, or just starting out in welding, this tutorial provides the knowledge and skills needed to create a high-quality coat rack from mild steel.

Difficulty: 1/10

Welding Process: MIG

Shielding Gas: 25% Carbon Dioxide and 75% Argon

Filler Wire: .035″ ER70S-3

Recommended Amperage: 140 amps

Wire Feed Speed: 200 inches/minute

Equipment Required

• 140 Amp MIG Welding Machine
• Grinder
• Circular Saw
• Wire Brush
• Welding Helmet
• Welding Gloves
• Welding Jacket/Apron
• Clamps

Consumables Required

• 1/4-in Mild Steel Plate
• Steel Hooks – Horseshoes, Chains, Rebar, etc.

Economics

• Estimated Cost: $15
• Expected Duration: 30 mins
• Sales Price: $40
• Profit: $25
• Hourly Rate: $50/hour

Preparation

Properly prepare your mig welder and gather all necessary safety equipment. This includes checking and ensuring that the welder is in good working condition, setting the appropriate parameters for welding mild steel, and ensuring that you have all necessary consumables, such as flux core wire.

In terms of safety, it is recommended to wear proper protective gear, such as a welding helmet, gloves, and long-sleeved clothing to protect against sparks and heat.

Additionally, the mild steel should be thoroughly cleaned of any rust or debris to ensure a smooth and clean weld. This can be done using a wire brush, sandpaper, or chemical rust remover.

Welding Pattern

The welding pattern required for this coat rack project will a series of straight welds, typically called “butt welds“. This type of welding involves joining two pieces of metal end-to-end, creating a continuous joint along the length of the metal. The butt welds will be used to join the vertical and horizontal pieces of the coat rack, forming the frame and ensuring its stability.

PRO TIP: Inspect your work regularly - Check the weld bead periodically to ensure it is smooth and consistent, and make any necessary adjustments.

Step 1: Cut the Steel to the Desired Size

There are several methods for cutting mild steel, including the use of hand-held cutting tools such as hacksaws and metal cutting saws, or powered cutting tools such as plasma cutters and metal cutting band saws. I just used a circular saw.

It is important to measure and mark the steel accurately to ensure that the cuts are straight and precise. Additionally, it is recommended to use proper eye protection and hearing protection while cutting, as it will generate sparks and loud noises.

For this project I cut the frame of the coat rack to be 36 inches long x 6 inches high and is made out of 1/4″ steel. This is going to have 3 hooks for coats. You can customize these dimensions to whatever size you want and any number of hooks. Just make sure there is enough distance between each hook.

Step 2: Clean and Prepare the Plates and Hooks

Remove Debris: Use a wire brush or sandpaper to remove any debris, such as rust, oil, or grease, from the surface of the steel plates.

Clean the Steel: Clean the surface of the steel plates with a degreaser or solvent to remove any remaining contaminants.

Dry the Steel: Thoroughly dry the steel plates with a clean cloth or compressed air to ensure that no moisture or residue is present.

Inspect the Steel: Carefully inspect the steel plates for any cracks, dents, or other imperfections. If any are found, they should be repaired or the plates should be replaced.

Prepare the Hooks: You can really use your creativity on the styling of the hooks. I have seen some great coat hooks made from bent rebar, horseshoes, or chains that have been spot welding into place. I am just using the same 1/4″ steel and bending them into shape.

Step 3: Weld the Hooks to the Frame

Align the Hooks: Align the steel frame and place the hooks in position one at a time. Measure accuratly to place them in the correct positions both horizontally and vertically.

Clamp the Hooks: Use the clamps to securely hold the hooks in place. Make sure the clamps are tightened enough to prevent any movement while welding.

Weld the Hooks to the Frame: Begin welding the hooks with tack welds to secure them. Keep the weld pool small and consistent, and make sure to maintain the correct travel speed and angle. Depending on the shape of your hooks will dictate how much welding is required.

Weld a Second Pass: After completing the first pass, inspect the weld bead for any defects or areas that need additional welding. Make a second pass if necessary, following the same procedure as the first pass.

Remove the Clamps: Once the welding is complete, remove the clamps and inspect the coat rack for any defects. If necessary, make any repairs and repeat the welding process until the hooks are attached securely and free from defects.

Step 4: Grind and Sand Welds

Let it Cool: Give it some time to cool completely before starting to clean and grind the welds.

Remove Slag: Use a chipping hammer or wire brush to remove any slag or debris that may have formed on the surface of the welds.

Clean the Welds: Clean the surface of the welds with a cleaning solution, such as a degreaser, to remove any oil, grease, or other contaminants. Rinse the coat rack with water and dry it thoroughly.

Grind the Welds: Use a grinder with a coarse grit sanding disc to grind the welds. Start by grinding along the length of the weld, holding the grinder at a low angle and using light pressure. Move the grinder in a circular motion to ensure that the weld is smooth and even.

Smooth the Welds: Change the sanding disc to a finer grit and repeat the grinding process, focusing on smoothing the surface of the welds. Apply light pressure and work evenly and steadily to achieve a smooth surface.

Step 5: Attach it to the Wall

You need to consider how you will attach your coat rack to the wall. For my design, I will simply drill a hole into each end of the frame and screw it into a brick anchor. My coat rack is relatively light, so if you have gone for a larger design you may want to use more than two screws and anchors. You can drill holes midway along the frame as well to increase its strength.

Inspect for Defects

A visual inspection is a straightforward and efficient way to detect surface-level defects in your welded hooks. During this process, watch for the following commonly seen issues:

Cracks: These can appear as straight or jagged lines on the surface and are present in the weld or base metal.

Porosity: This issue is caused by entrapped gas and appears as small circular defects in the weld bead.

Undercutting: This defect happens when the base metal around the weld has been melted away, resulting in a groove along the edge of the weld.

Overlap: This occurs when two separate welds overlap, forming a ridge or bump on the surface.

Lack of Fusion: This issue arises when the weld bead does not bond properly with the base metal, creating a gap between the two.

Final Touches

Paint the coat rack to prevent corrosion and rust. I prefer a matt black paint, but I have seen some great designs done with a silver. You can choose any finish that suits your tastes.

Other Designs for Inspiration

Frequently Asked Questions

How can I ensure that the welds are strong and durable?

It is important to use proper welding techniques and to use the correct settings for your mig welder. This includes using the appropriate filler material/welding wire and ensuring that the metal is clean and free of debris. It is recommended to make multiple passes over the joint, rather than attempting to make one continuous bead, as this will help distribute the heat and prevent warping or cracking of the metal.

After welding, allow the metal to cool slowly to room temperature to prevent thermal shock, and perform performing a visual inspection to ensure high-quality of the welds.

Conclusion

Welding a coat rack out of mild steel is a simple but rewarding project that requires proper preparation, attention to detail, and proper use of welding equipment. By following the steps outlined in this tutorial, you can ensure that you have the necessary tools and materials to complete the project, and that you are taking the appropriate safety precautions.

With the proper technique and attention to detail, you can create a functional and stylish coat rack that will be the centerpiece of any room. I have found these can also be appreciated gifts or can be sold at your local market.

The post How to Weld a Coat Rack [Welding Project] appeared first on Beginner Welding Guide.

With patience and attention to detail, you’ll be well on your way to creating beautiful and functional bookends that you can display with pride or sell for a profit.

Project Overview

A pair of decorative and functional bookends, made of durable steel and incorporating a unique touch with a spare gear or spanner.

This is an ideal project for a novice welder, even as your first ever project. It is simple and doesn’t involve any advanced techniques or difficult patterns. You can adjust any dimensions and design to suit your personal preferences.

Difficulty: 1/10

Welding Process: MIG

Shielding Gas: 25% Carbon Dioxide and 75% Argon

Filler Wire: .035″ ER70S-3

Recommended Amperage: 125 amps

Wire Feed Speed: 200 inches/minute

Equipment Required

• 140 Amp MIG Welding Machine
• Grinder
• Circular Saw
• Wire Brush
• Welding Helmet
• Welding Gloves
• Welding Jacket/Apron
• Clamps or Magnetic Squares

Consumables Required

• 30-in x 4-in x 1/8-in Mild Steel Plate
• A Spare Feature – Spanner, Gears, Horseshoes

Economics

• Estimated Cost: $15
• Expected Duration: 25 minutes
• Sales Price: $40
• Profit: $25
• Hourly Rate: $60/hour

Preparation

Assemble all the welding equipment and test it – make any necessary adjustments to the settings. Your workspace should be set up with proper ventilation and lighting, and the steel plates should be cleaned and prepared by removing any rust or debris.

You should practice welding on scrap materials to warm up and test settings before starting the project if you are hesitant.

Welding Pattern

Today we will focus on a ‘straight’ or ‘back-and-forth’ pattern (also known as a weaving pattern) for this project.

PRO TIP: Properly prepare the joint - Square the edges of the metal pieces and bevel them if necessary to ensure proper penetration.

Step 1: Cut the Steel to the Desired Size

There are two main design considerations – selecting either an ‘L’ shape or a ‘T’ shape. The T shape gives more stability but is less attractive, in my opinion. The choice is purely up to you and what you want the final design to look like. Keep in mind, there will be minimal force coming back from the books.

For my project, I have taken a height of 6-inches for the vertical plate, and 4-inches for the horizontal.

Mark the cut line on the steel with a pencil, making sure it is straight and accurate. Place the steel on the saw bed and align it with the blade. Turn on the saw and carefully guide the steel through the blade, keeping the cut line aligned with the blade.

It is important to take your time and be precise in your cuts.

Step 2: Clean and Prepare the Plates

Remove Debris: Use a wire brush or sandpaper to remove any debris, such as rust, oil, or grease, from the surface of the steel plates.

Clean the Steel: Clean the surface of the steel plates with a degreaser or solvent to remove any remaining contaminants.

Dry the Steel: Thoroughly dry the steel plates with a clean cloth or compressed air to ensure that no moisture or residue is present.

Inspect the Steel: Carefully inspect the steel plates for cracks, dents, or other imperfections. If any are found, they should be repaired or the plates should be replaced.

Prepare the Joints: If welding T or L-shaped bookends, prepare the joints by beveling the edges of the plates to be joined. This will create a V-shaped groove, allowing for better penetration and fusion of the weld bead.

Step 3: Weld the Bookend Together

Align the Plates: Align the steel plates and place them in the desired position, ensuring they are in the correct T or L shape.

Clamp the Plates: Use the clamps to securely hold the plates. Make sure the clamps are tightened enough to prevent any movement of the plates while welding. A good option is using a magnetic square tool to align the plates.

Weld the Plates: Start by tack welding each corner to keep the pieces aligned. Then weld the plates from one end, working steadily and slowly along the joint. Keep the weld pool small and consistent, and maintain the correct travel speed and angle.

Weld the Second Pass: After completing the first pass, inspect the weld bead for any defects or areas that need additional welding. Make a second pass if necessary, following the same procedure as the first pass.

Remove the Clamps: Once the welding is complete, remove the clamps and inspect the bookends for any defects. If necessary, make any repairs and repeat the welding process until the bookends are of good quality and free from defects.

Step 4: Weld the Styling On

Now is the time to weld the styling on. The most common styles I have seen is to cut an old gear into 1/4, and to cut a spanner in 1/2, and weld one piece onto each end.

Cut the Gear or Spanner: Use a metal cutting saw, grinder, or torch to cut the gear or spanner along the marked lines. Wear appropriate safety gear, such as gloves and eye protection.

Clean and Prepare the Pieces: Clean the gear or spanner cut pieces to remove any debris or residue. Inspect the pieces for defects or imperfections, and make necessary repairs.

Clamp the Pieces: Clamp the gear or spanner pieces to the bookends, ensuring they are in the correct position and aligned with each other.

Weld the Pieces: Begin welding the gear or spanner pieces to the bookends at one end, working steadily and slowly along the joint. Keep the weld pool small and consistent, and maintain the correct travel speed and angle.

Step 5: Grind and Sand Welds

Let it Cool: Give it time to cool completely before cleaning and grinding the welds.

Remove Slag: Use a chipping hammer or wire brush to remove any slag or debris that may have formed on the surface of the welds.

Clean the Welds: Clean the surface of the welds with a cleaning solution, such as a degreaser, to remove any oil, grease, or other contaminants. Rinse the bookends with water and dry them thoroughly.

Grind the Welds: Use a grinder with a coarse grit sanding disc to grind the welds. Start by grinding along the length of the weld, holding the grinder at a low angle and using light pressure. Move the grinder in a circular motion to ensure the weld is smooth and even.

Smooth the Welds: Change the sanding disc to a finer grit and repeat the grinding process, focusing on smoothing the surface of the welds. Apply light pressure and work evenly and steadily to achieve a smooth surface.

Inspect for Defects

A visual inspection is a simple and effective way to check for surface-level defects in the welded bookends. During a visual inspection, look for the following common defects:

Cracks in the weld or base metal can be visible as straight or jagged lines on the surface.

Porosity refers to small holes or voids in the weld caused by entrapped gas. It appears as small, circular defects in the weld bead.

Undercutting is a condition in which the base metal around the weld has been melted away, creating a groove along the edge of the weld.

Overlap occurs when two separate welds overlap one another, creating a ridge or bump on the surface.

Lack of fusion occurs when the weld bead does not properly adhere to the base metal, creating a gap or separation between the two.

Frequently Asked Questions

How should welding equipment be tested before use?

Check for damage or malfunctions: Inspect the welder for any signs of damage or wear, and ensure all connections are secure.

Verify settings: Ensure that the voltage, amperage, and wire speed settings are appropriate for the materials and thickness.

Test the wire feed: Connect the spool of welding wire and check that it feeds smoothly and continuously through the gun and nozzle.

Check the arc: Strike an arc on a piece of scrap metal and adjust the voltage and wire speed if necessary to achieve a smooth and stable arc.

Check for gas leaks: If using a gas-shielded MIG welder, check for leaks in the gas supply system.

Test weld: Make a test weld on scrap metal and examine the resulting bead for consistency and quality. Make any necessary adjustments to settings before starting the main project.

Conclusion

By following the steps outlined in this tutorial, beginners and experienced welders alike can successfully produce high-quality bookends that are both functional and stylish.

It is important to properly prepare the materials and equipment and to follow all safety guidelines. During the welding process, it is important to pay attention to the weld pool and ensure that the correct settings are used.

After the bookends are completed, it is essential to perform a thorough inspection to check for any defects and ensure they are of good quality and suitable for use. With these tips in mind, welding bookends can be a fun and rewarding experience, resulting in a unique and beautiful addition to any home or office.

The post How to Weld Bookends [Welding Project] appeared first on Beginner Welding Guide.

Welding as a skill is in high demand, and companies from manufacturing brands to utility companies are always looking for qualified welders. Even if you don’t want to become a professional welder, you can still make money by hiring out your skills or working on projects that you can sell.

If you’re thinking of turning your welding hobby into a way to make money, here is your guide to getting your business off the ground.

How to Make Money Welding at Home

To make money welding, you can obviously become a professional welder. Welding is in very high demand as a profession since so many industries need it, and not enough people are trained for it. However, entering professional welding requires extensive technical training and even a degree. 

If you don’t have time for going through training or are happy with your current career, being a professional welder is not for you. However, you can still make money by welding at home. Here are a few ideas for how to do so:

Make and Sell Welding Projects

One of the simplest ways to make money from welding right out of your garage is to make and sell welding projects. You have complete creative control in this form of welding as you decide which products you want to make. You can create everything from functional shelving to metal art. 

However, it takes time to figure out how you’re going to sell your projects. You can look into local craft fairs, take orders online, or ask your friends and neighbors if they want to buy your stuff. This can be a great source of supplemental income, but it requires work to create projects and build your business.

Sell Your Services

Besides selling your projects, you can also sell your services as a welder. Ask around if anyone needs stuff fixed. It’s a great way to make a quick buck while helping out your neighbors.

Do Contract Work as a Welder

If you are a very skilled welder and have some training, you can get into semi-professional work without leaving your own workstation. Some companies hire welders for contract work, and depending on the project, you could do your work from home instead of going into a factory or workshop. Research welding careers and see which niches are a fit for your interests and skill set.

Elements of a Profitable Welding Project

If you are serious about making money from your welding, you can’t just focus on your passion projects. Although you should like what you are doing, you also have to think about what will help you make money. Here are some elements of profitable projects that can help guide what you will do next. 

Demand

You want to make projects that you know people will want to buy. Think about what is popular where you live. If you live near a lake or beach, you can make anchors or other accessories for people’s boats. If it’s something that your friends and neighbors might want, chances are, there are other people who feel the same way.

Low Costs

When you’re welding with the goal of making money, you have to think about profit. If you spend a lot of money making the project, you won’t have a lot of profit unless you raise the price very high. Try to save money on materials whenever possible, so choose projects that have accessible materials. You can even make fun things reusing scrap metal!

Custom and Special Details

Finally, a profitable welding project will be one that stands out enough that people are willing to pay money for it. Something you make will always be pricier than what someone can get online (unless you cheat yourself in your pricing). However, people are willing to pay more for something special. Offer customization or special details that mass-produced welding projects can’t replicate, and your customers will be happy to pay whatever you ask.

These are just some guidelines to help you decide which welding projects could be profitable. If you are starting a business, figuring out what you will sell is a process of trial and error. You might need to adjust what you are making depending on what people around you are willing to buy. 

Before you start welding, ask around. Be direct, tell people you are thinking of welding for money, and ask what they would buy. That can give you an idea of projects that would sell.

1. Basic Shelving

You don’t have to have years of experience to start making money welding. With these simple projects, you can sell your work for a profit and awe others who don’t know how easy they were to put together.

Putting together some very basic shelves does not require extensive experience. If you’ve already created shelves for yourself to organize your garage or workspace, why not offer the same service to other people? Many people don’t care about shelves looking pretty; they need something to help them organize clutter. 

Offer customizable shelves where clients can adjust the size and number of shelves according to their needs. They may not have pretty details if you’re still a beginner, but they will still be sturdy.

2. Small Decorative Items

Some of the best projects for beginner welders are small decorative items. They don’t require lots of materials so you can turn a profit because you don’t spend lots of money on the project. They are simple and quick to execute. Plus, they are more forgiving of mistakes because they don’t have to bear weight like other projects such as furniture do.

You can offer many different decorative items or focus on just a few specialties. This category is broad enough that you can play around with whatever strikes your fancy. For example, you can make storage racks for different items such as wine or firewood, or items like bookends or coat racks.

3. Tables

If you’re confident in your welding skills, you can move on to making and selling furniture. Choose furniture that is as simple as possible, such as desks and coffee tables. All you have to do for tables is weld the legs into a sturdy frame, then add the tabletop. It is a larger project that requires more material but easy enough to execute once you have basic welding skills.

Once you have intermediate welding skills, you have many more options in terms of projects you can build. Here are some profitable ideas that will wow the people around you.

4. Stools

Once you are comfortable with the basics of welding and making furniture, you can make more complicated furniture such as chairs and stools. Stools are a bit more complex, but doable, because you have to install the legs at an angle. Plus, they are fun little projects that don’t require a lot of material but are very popular.

5. Garden Accessories

If you know many passionate gardeners, you can make money by making garden accessories. Trellises, arcs, and supports are important to help tall plants grow properly. They don’t require a lot of material but are a bit finicky since the rods are so delicate and require shaping. You can also make garden signs and offer to customize them for your customers.

6. Fire Pits

Fire pits are a great accessory for every backyard. They are a conversation starter, a place to warm yourself on chilly nights, and even a great place to make smores. Fire pits are also very simple to construct. All you need is the trough or pit and some legs. Making the pit’s shape might be harder for a beginner, but it is just the right challenge for an intermediate welder.

7. Basic Art

Most people think of welding as a purely functional skill. However, you can use it to make beautiful art. Welding for art is a different set of skills than purely functional welding, but you can master it once you have the basics down. Weld together different metal pieces to make flowers or create basic lawn ornaments. People love eye-catching, unique artwork they know they can’t make at home, so you can sell these at a profit.

Once you master the skill of welding, you can make pretty much anything you set your mind to. Challenge yourself with these welding projects.

You can also charge a higher price for challenging projects because you are investing more skills and time into your work. Plus, people will be awed at your skill and more willing to pay the higher price. If that’s not an incentive to get better at welding, I don’t know what is.

8. Welding Portraits

Once you have complete control over your welder, you can move on to making advanced welding art. You can make complex sculptures with fine details. You can even make portraits! People will commission you to make portraits of your loved ones. Then, you will use a welding machine to engrave their faces into a sheet of metal.

Welding portraits requires artistic skill as well as control over the welding bead, which is often difficult for a beginner to master. Portraits are a great way to show off your skill. Plus, because they are custom-made, people will pay you good money for them.

9. Outdoor Cooking Equipment

Once you have mastered welding, you can make complex, functional items. One application for your skill is outdoor cooking equipment. Make custom grills, smokers, and outdoor stoves for people. These projects demand skill because not only do you need to make something that looks good, but it also needs to be functional. You need to create an item that stores fuel, ignites properly, cooks food, and protects people’s safety.

While making smokers, stoves, and grills is more complicated than other welding projects, it is also more rewarding because you are challenging yourself. These items are also very profitable because people will pay a lot of money for them, especially if you are making a custom grill to fit someone’s specifications.

10. Workshop Tools

One important audience you can tap into when selling your work is other people who are welders or DIYers. Make tools, stands, and mounts that can make their projects easier. These people are also more likely to appreciate your work and be willing to pay more.

For welders, you can sell custom-made welding carts. For DIY handymen, tool racks, vice mounts, and other workshop equipment are helpful. You can even cater to hunters by selling deer hoists and other tools that make it easier to break down game after hunting.

11. Vehicles

Once you have advanced welding skills, you can make more complex functional projects, including vehicles. These projects are large, making them more difficult to manage, and contain a lot of moving parts. However, they are also in high demand.

One relatively simple project you can do is making a trailer. If you live in an area with lots of farmers or handymen, there will always be a demand for trailers. Make simple flat-bed trailers or more complex utility trailers for people hauling tools.

If you want to challenge yourself, you can even make your own bikes and tandem bikes at home! They won’t be as advanced as competitive road cyclists’ bikes, but they are still a nice way to show off your skills. Some people may want them as decorative pieces for the garden.

Final Thoughts

Not only is welding a creative skill, but it is also a skill that can make you money. Even if you decide not to become a professional welder, you can make money from home by offering to conduct repairs or selling your projects. There are projects for every skill level and interest. The hard part is deciding what you want to make!

The post 11 Welding Projects to Make Money from Home appeared first on Beginner Welding Guide.

The article details step-by-step guides of two beginner welding projects – a bowl and a cube.

So you have decided to weld. You’ve done your research and you know the difference between MIG, TIG, and stick welding.

You decided on a good welding machine to practice with and you are wondering what now?

Well, as your friendly professional welder, I am here to help. The best way to start welding… is, well, to weld! And I know that sounds like the obvious answer.

Just stay with me here…

Let’s start using your welder so you get comfortable with it. You’re going to want to practice many many things and tackle them step by step.

Beginner Welding Projects For You

I’ve been using these very same  projects for many years to train new welders and they teach you all the basics like:

• proper cutting of stock metal
• proper preparation of the metal to be welded
• correctly fitting joints together
• use of magnets
• use of clamps
• role of a good hammer
• safe welding habits
• essential welding gear

I promise that you will make some mistakes along the way and that’s good!

These projects are designed to challenge you and build your welding skill set.

So let’s dig in and dive into my favorite beginner projects, and I have two that stand out right away.

The first project I have is The Bowl, and the second is The Cube.

I have also written a guide focusing on beginner welding projects that make money if you are looking to generate an income from your welding skills.

First Beginner Welding Project: The Bowl

The bowl is really an excellent beginner’s project for several reasons. It teaches you these basic skills:

• Safety
• Proper body placement to a stagnant project
• Proper handling and using a MIG gun
• Supporting your hand using a workbench
• Viewing a project through a hood for the first time
• cleaning and prepping your materials
• laying out your project.
• Use of wire snips.

When you’re done, you’ll have a great-looking bowl, like this:

Equipment Required

• MIG Welding Machine
• Safety gloves
• Welding Hood
• Wire snips
• Metal washers of mild steel of different sizes. I’ve used two sizes in the past for best results.
• A steel mixing bowl
• A welding table

1. Plan your workload out

Even before you grab your welder, you want to take your washers and lay them out.

When you unpack your washers you’ll want to wipe each one down with denatured alcohol. The DNA (Denatured Alcohol) clears away all the dirt, dust and grease off the surface of your metal and you will have a good, clean weld.

I have two sizes for my bowl.

2. Arrange washers inside a mixing bowl

Once you prep your metal grab your mixing bowl and arrange your washers inside the bowl.

Like this:

Make sure they are laying flat on the sides. Your washers will sit on top of each other without collapsing.

NOTE: The idea is to get a pattern with the two sizes that you like.

3. Prepare your Equipment and Protection

Once you’ve got an arrangement you like, you can go ahead and suit up!

Get your hood, jacket, and gloves on.

4. Start Welding

Make sure you set the ground clamp to your workbench and you’re ready to begin.

The great part about this project is that every washer you are going to connect will be with a tack weld. Many people confuse tack welds and spot welds – I did for a good year!

So here is a good way to remember them. A good way to start is Top Down.

Like this:

Why?

Because welding metal, in general, makes the metals pull together so as you tack weld your washers they will want to pull off the wall of the mixing bowl. As you weld, you can gently push them back against the mixing bowl which will maintain the shape of your project,

If you work bottom-up you run the risk of the top collapsing and falling down so you’ll have to set up all your rings again.

In Conclusion

Tack weld the first row (working in a circle). Left to right or right to left – there is no wrong way here. Focus on creating nice tack welds to hold your rings together.

That is the entire process!

It’s great because you have all the time you want to focus on nice tack welds.

Now, this is a pretty simple project, and that’s good. Your new bowl should look something like this:

You want to make sure you are doing everything correctly and with full understanding.

So after a few hours, you’re going to be tired. This small project is perfect for your first time on the floor.

Now, another important piece of this project is: It’s fully complete in one session. When you’re done – you have a great-looking bowl.

You’ll be proud to put it on your table and show off your new skills. These small wins are important when building a new skill set.

When you have a visual reminder in your daily space it does three things:

1. It demonstrates your commitment to your new skillset.
2. It reminds you to practice.
3. It shows that yes, you can weld!

Skills you are using in this project

The bowl helps you focus on two key skill sets :

• Your body posture and vision ( how you stand holding your MIG gun and see through your hood)
• Completing your tack welds

Body Posture

Let’s talk about body positioning in relation to a workpiece. Since everyone is built a little different let’s focus on the welder itself.

1. You want to position the tip of the MIG gun anywhere from ¼ to ¾ from the workpiece.
2. You want to hold your gun at 90 degrees to your workpiece. At this distance, you are going to make a short circle to complete your tack weld and you are going to be listening for that short “bacon” sizzle.
3. Get comfortable while welding – Fatigue leads to injury. You do not want to unnecessarily fatigue your hands, shoulders or any part of your body. Use two hands to support your MIG gun and have yourself positioned in front of your weld. It might take some time to get comfortable with your positioning to your work and that’s ok. It’s part of the process.

Now that we talked about being comfortable, let’s look at this project for the short tack welds and your hood. As a new welder, it will take some time to get used to the auto-dark features of your hood and focus on your weld.

The short tack welds will get you used to the hood going dark and light quickly.

Why are Tack Welds important?

The basic idea of a tack weld is to hold two pieces of metal in place until you can bead weld it. You are heating the metal and add filler to a specific point. When you tack the piece together your basically setting yourself up to bead weld.

Now when working on a larger project tack welds hold your project together before final assembly.

So good tack welds will be strong enough to support the project but it will also be easy enough to break!

If the alignment, angle, or position of your metal is off you can easily remove the tack weld and reposition the metal for another tack.

Another way to think of tack welds is like building blocks. They are the basic weld before beads.

So before learning how to properly bead weld, learning how to tack weld is the first important step.

Safety

A lot of folks want to jump right into welding and that’s great. I can’t think of an industry that’s as fun and rewarding as metalworking. So making sure you have the right gear will keep you welding for a long time. Read my post about protective equipment for welders.

Let’s talk about each piece.

1. A good pair of MIG gloves will save your hands from spatter. They are cost-effective, durable and will ensure your hands are protected yet flexible enough to hold the MIG gun and handle your project and tools.
2. You’ll also need a good welding hood. Welding emits a UV light can permanently damage your eyes. This is one area that you need to purchase a quality one and they don’t have to be expensive to be good.
3. You’ll need a jacket and safety glasses too.

A good choice for a jacket is the BSX entry-level jacket. It’s 100% cotton, easily washable, and will protect you from spatter and slag.

Regarding safety glasses, A good entry-level pair will do just fine and pick up two or three. Once they get scratched, they are no good.

Second Welding Project for Beginners: The Cube

Moving forward, let’s jump into the next project. This project can definitely work for a beginner. However, I like this as my second project.

It builds on all the skills we practiced for the bowl.

In this project you’ll be:

• standing longer
• tack welding
• Bead welding
• fitting together and clamping your pieces
• grinding down your welds…

If your ready for The Cube, let’s dive in!

Materials and Equipment

• 8 gauge ½ tube – you’ll need about 9 feet
• A band saw or a Sawzall or, the most basic: a hacksaw.
• A vice
• A belt sander or an angle grinder with 36 grit paper or a cutting stone
• Small shop magnets
• Ball peen hammer or a lightweight hammer
• Clamps, minimum of 2
• Welder
• Your safety equipment.

Now, let’s plan out your workload on this project. Once you’ve purchased your 8 gauge metal you’ll want to draw some rough blueprints.

1. Cut your metal

You’ll be cutting (4)  4” posts ( straight cuts) and (8) 45-degree miter cuts @ 6 inches.

So you’ll end up with parts that look like this:

2. Bevel your cut parts

Now you’ll want to bevel the edges on your material. You’ll take your post and bevel two joining sides.

Something like this:

and you’ll bevel the opposite corners on your miter cuts:

Like this :

Why exactly do you need to bevel edges before welding?

You want to create a groove for your weld to sit in. So once you tack your piece together, you’ll have a channel for your bead to sit in nicely.

4. Clean your parts

After you cut your material you’ll want to clean them with Denatured alcohol. It is used to clean the dust, dirt, and mill scale off your material. When you have any impurities on your metal it could compromise your weld and we don’t want that.

So clean metal is the way to go. You’ll have the best chance at creating a nice solid weld.

Once you have all your parts together, you can lay them on your work table.

5. Tack Weld

Firstly we are going to tack weld the two miter cuts.

You want to grab (2) 45-degree pieces and join them together like so:

Make sure they are joined with a magnet.

Now, you’ll want to tack weld then end furthest from the magnet. They can affect your arc, so you’ll remove it after your first tack weld.

Now, you’ll drop another tack weld on the other side of your joint.

Like this :

Once complete you can place your newly joined angle aside.

Let’s repeat this process three more times.

6. Join corners together

The next step will be to join our corners together. We will grab our magnet again and use it to join our parts into a square.

Like this :

Again, we will be using tack welds for all of this. Once complete we will lay some beads to tie it all together.

When we have one square repeated we can repeat this process. When we are done, we should have our cube’s two sides (top and bottom) complete. It should feel good to see our cube coming together at this point!

7. Attaching posts on completed sides

Let’s move on to the next stage of assembly. We will grab one of our completed sides and rest a post on the corner, like this:

A magnet will be helpful for alignment.

NOTE: Make sure to align the post with the outer plane of our cube So it will be flush.

Once you feel comfortable with the position, you’ll tack weld the post in two locations. Repeat this process on the opposite corner of your side.

When complete you’ll have all four posts welded. Two on each side of our cube.

The reason for this is so we can fit our cube together easily.

8. Use Clamps to tighten down cube

Well, our cube will not sit together perfectly when we test fit it.

So we will have to use our clamps and we can tighten down our cube as necessary.

I placed a clamp on the above cube on the left side to get the post nice and tight to the top of our cube.

If you still need to do some adjustments to the posts then don’t be afraid to tap your posts with the hammer.

REMEMBER:  we tack welded this so that we can make these adjustments.

If we laid a bead down right away we would not be able to fit this together.

9. Bead Welding

Once you’re satisfied with the fit…

You guessed it.

Time to tack your posts down so you have a solid cube. When you’re done you can remove your clamp.

You’ll have a cube that looks like this :

Looking good so far!

Let’s talk about finishing up our welding on this Cube!

If you’ve built the first project with me, the bowl, and now your completing the cube, this will be your first time welding beads and that’s exciting!

Remember your hand positioning and your MIG gun position and listen for that bacon sound! If you placed your tack welds at the ends of your pieces you’ll have a good starting and ending position for your welds. Now it’s a matter of running a bead from tack to tack to complete the joint.

You’ll repeat the process for each joint you have and don’t worry about the inside joints. if you remember, we didn’t create a channel for them – so no need to weld them.

When you are done, your Cube should look like this :

10. Grinding

Once you’ve cleaned your workspace, it’s time to finish your cube. The first step will be to secure your cube to your work table.

Safety first!

You’ll be using an angle grinder to knock down your welds. And these can be super dangerous so be sure to use both hands on your angle grinder and wear your safety glasses.

An as always, make sure you are in a comfortable position. I like using the Dewalt angle grinder because it has a deadman switch for extra safety and no lock to keep the angle grinder automatically engaged.

Once your cube is clamped down, you can begin to knock down your welds. The best way I found to use the angle grinder is :

Your right hand will apply the pressure and your left hand will provide direction. With a few passes of the angle grinder, your joint should look like a solid piece of steel.

Like this:

What you’ll do next is repeat this process for each weld you created.

In the end, you’ll have a cube that looks like this:

And this would be a great place to End your first project.

TIP: I would spray the entire work with a light coat of clear coat - just to prevent rust.

11. Optional step before clear coating – Sanding

You can use an orbital sander and some 40 grit paper to go over your welds. After you run a 40 grit pad over the entire cube I would then run an 80 or 100 grit Pad over the cube one more time.

That would really give it a nice rough finish. It would be perfect at this point for a clear coating or a patina and wax treatment.

Either way, when you finish your cube you’ll have a great project you just completed.

This project is great because you’ll really get comfortable welding here. You will have practiced cutting down stock and fitting it together with laying tack and bead weld.

You’ll also see how the heat can pull and warp the metal and how to fix it.

Conclusion

Both of these projects: The Bowl and The Cube are great beginner’s welding projects.

I like them and use them for my new welders because they really get you comfortable not only on the fabrication floor but actually welding.

The Bowl gives you the confidence of laying good tack welds, body positioning, and welding through a hood for the first time. Best of all you will complete the bowl in under two hours.

The Cube is excellent because you built on the welding skills set. It should take you about 4 hours to complete the cube and you’ll be laying tacks, laying beads, fitting together joints, and how to grind down your welds.

With the skills, you learn on these small projects you’ll be able to tackle larger, more complicated projects in a short period of time.

Read Next

• Which welding Method and Metal is Best for beginner artists?
• What do I need to start welding?
• 8 Tips for MIG Welding Beginners
• Why Use a Welding Apron?
• A Beginners Guide to Welding Chromoly
• How to select Welding Amperage?
• 5 Beginner Welding Mistakes
• Differences Between Welding Brazing and Soldering
• A Welding Guide for Beginners
• A Beginners Guide to Welding Aluminum
• 101 Welding Tips

The post 2 Easy MIG Welding Projects for Beginners appeared first on Beginner Welding Guide.

Steel is a great medium to work since it is so forgiving. If something needs to be added, in order to lengthen or shorten it, or even if you need to bend certain pieces, steel is the way to go. I would recommend using either MIG or TIG welding for your projects since they are relatively easy welding methods for beginners.

How to Choose Right Type of Metal for Your art?

The artist’s decision on the type of metal to use will be based on the effect he or she wants to achieve, whether for aesthetic or utilitarian reasons.

Keep this in mind when choosing the right type of metal for your art:

Strength and toughness

Your art should withstand wear and tear from usage or from exposure to weather conditions.

Resistance to corrosion

More resistant materials have the ability to fight the effects of water and other elements which results in deterioration. For you as a welding artist, this means less need for surface treatments such as painting or powder coating your art.

Weight

Expensive metals that are strong and highly corrosion-resistant tend to be heavier than cheap materials that are softer and inferiorly crafted. You need to consider weight in an art piece because it affects its ability to stand independently without a support structure under it. Even if a weld material has a high strength, it’s still unsuitable if the weight is too much for the art’s support system to bear.

Stability

Your material should retain its shape and not deform even when under great stress.

Reactivity with other elements/chemicals

Some materials react with chemicals in the air, water, soil, etc., which will damage their surface over time. Low-reactiveness means a longer life span as it won’t deteriorate as quickly as those made from reactive metals such as aluminum. In welding arts, this is especially important for you if the artwork will be placed outdoors.

Formability

Metal Formability is really important. It is the ability of a metal to form or bend without breaking apart or reverting back to its original shape once the stress is removed.

Ease of application

Some welding materials need more delicate handling because they can break easily if not treated carefully. Such metals are not ideal for large-scale applications such as those on sculptures and bridges. Other materials, such as titanium, require very specific cutting techniques using saws that work only with this material.

Cost

Expensive metals are usually harder and more durable than those that cost less. For welding arts, the temperature resistance of a material may be a very important factor if it is planned to be used in large outdoor projects where environmental factors such as heat exposure could damage its surface.

If you are looking to make money from your welding art, I have put together this guide you may find useful.

Most Popular Type of Metals Used in Art

There are many different types of metals used in art. These metals can be made into various forms or used to make various objects. Many of you might think that the only metal that is used in art is aluminum. That is not true!

Aluminum can be painted on and stuck onto many different types of materials, but it’s not the only metal you will find in art. Read on to find out which metals are used in art, and what you can do with them.

Steel

Steel is a common metal used in welding processes because of its strength and high resistance to surface breaking however, steel rusts quickly if not handled carefully so it’s usually left unpainted after being processed so as to avoid any unwanted reactions from the elements during outdoor installations.

Aluminium

This metal might seem cheap and flimsy, but Aluminium can take quite a bit of punishment before breaking apart completely. It is typically the cheapest metal you will find anywhere so this means that people who want their art projects done quickly will use this type of metal instead of any other because they won’t end up spending too much time working with it.

Aluminum is easy to cut with most tools, but one thing you will need to remember about this material is that it can easily rust or corrode if left unpolished for too long. It’s also extremely lightweight, so the finished project will not be as heavy as many of the others you might create over time.

It can be made into thin sheets without much difficulty, making it easy for artists/welders to work with aluminum when crafting organic forms. Aluminum has high heat conductivity so it can be difficult to adjust the temperature of its surface for specific effects without changing its overall color.

NOTE: Welding aluminum tends to produce anodized finishes, creating different colors through chemical treatments which is useful when welding metals like stainless steel and other types that don't easily take on color after processing unless heated up to extremely high temperatures.

This particular metal should only be used if your goal is to create something that is very simple and does not require a lot of strength or durability.

Stainless Steel

Stainless Steel is another type of metal artist use in their projects. Its low-ductility makes it difficult to work with compared to aluminum but it makes up for this quality by having higher tensile strength.

This metal type is ideal for outdoor art installations where environmental factors such as sunlight exposure could be potentially dangerous (e.g., rust.)

Copper

Copper is one of the most commonly used metals for welding arts because you can hammer, bend and mold it to create different shapes without too many difficulties.

It won’t rust over time, so you don’t have to worry about using this metal in your art projects. One thing you should know about copper though is that while it looks great when created into small shapes and forms it doesn’t have much strength or durability when compared to other types of metal.

Depending on how it looks after processing, copper often takes on an orange-like color when heated, making it aesthetically pleasing when in contact with other metals such as stainless steel and aluminum that do not easily take on colors and/or decorative markings.

NOTE: Copper can't really be used to create anything that has a lot of weight to it. It should only be used for smaller things that are still beautiful, but not meant for items you plan on using every day.

Titanium

It’s not the most common of all metals, but it is one of the coolest looking. When titanium is polished to a fine point it is actually considered to be white, but when left unpolished it is gray in color.

Titanium can be used to create all kinds of things, but most commonly, it is used for jewellery that is either very simple or at least has a very plain design. This metal can be made into many different shapes and forms if you know how to work with it right.

It has high heat conductivity, so when heating it for texturing effects during the sculpting process, surface temperature has to be carefully controlled in order to avoid changing the metal’s overall color.

TIP: It will never rust or corrode like other materials might, which means that you can use it in the art without having to worry about the color fading over time. At least not for a very long time.

Iron

This metal is one of the most commonly used worldwide because it’s one of the cheapest. It doesn’t take much to create something out of iron, which means you can use this material without spending too much time or money on it. It can be polished or unpolished, depending on what your goals are.

Iron is slightly heavier than aluminum, but because it is considerably stronger, it can be made much smaller, so people won’t notice the difference when picking up the completed piece once it has been formed.

TIP: It's surface tends to take on an aesthetically pleasing red color after processing without much additional chemical treatment needed so it's commonly used for welding arts involving organic materials like wood, bone, stone and clay.

Brass

Brass is another metal alloy that welders use for an aesthetically pleasing result. This material has a yellow-like color when heated, similar to copper but with greater resistance from corrosion and rusting effects from environmental exposure such as rainwater damage.

Brass does not easily take on decorations or colors unless treated with chemicals before heating it up, which makes this a good choice for welding arts involving organic forms.

How big will your metal art projects be?

The best welding method for a future metal artist to learn is dependent on the size of the largest projects he or she is interested in creating. If you already know exactly what type of projects you want to create the choice should be fairly easy. If you are not sure, the decision becomes a little more difficult.

For starters, let’s look closer at a few scenarios.

Oxy/Acetylene Welding

For the beginner, this may be the best place to start for several reasons. When you purchase a good welding/cutting torch kit it should come with all the hardware (less bottles**) necessary. Necessary to not only gas weld, but by attaching the cutting torch, you can cut steel for your projects.

The cutting torch can also be used for heating up steel, red hot, to bend and shape it. You will not be able to weld large, thick pieces of metal together, but you can weld, smaller, thinner items all day long.

NOTE: Kits that come with the small bottles will be too small and limited on gas volumes. It is typically best to simply rent larger bottles from a nearby welding supply store. The larger bottles will cut down on the number of times per year you will need to carry them back to be exchanged for full ones.

MIG Welding

MIG welders are now the number one type of machine for industrial welding. The continuous wire feed and clean, slag-free welds save time in the welding shop. MIG welders come in 115v and 230v options.

If all of your weldings is expected to take place indoors on metals 1/16″ to 1/8″ thick, I suggest a 115v MIG welder using shield gas with .025 diameter wire. The smaller wire will make it easier to weld the thinner material. .030 wire will have a higher deposition rate and could also be used.

If all of your welding is expected to occur indoors on metals 1/8″ to 1/4″ thick, I suggest you step up to a higher capacity 230v machine using .035 diameter wire. This amperage and wire diameter upgrade will allow you to make fewer passes on thicker metals.

In reality, since most art projects do not require that the weld be as strong as the base metals, you can get by with, “Sticking together,” even thicker pieces as long as, if the weld fails, it can do no physical harm to anyone.

TIP: For additional information on MIG welding, read MIG welding – Gas or Flux Core? & 8 Tips for MIG Welding Beginners

When to Use Electrode Welding in Art?

Unless, as an artist, you desire to weld large sculptures for front yards or parks, you probably can get by with a MIG welder. However, you may need to switch over to flux-core wire to weld thicker metals when outdoors. That is another feature that makes a MIG welder a great choice for artists.

Personally, for larger projects that need to be welded with strength, I prefer electrode or stick welding, as it is also called. It may just be that I cut my teeth stick welding, but given the choice, that is what I will choose every time. The welding machine I would use would be an AC/DC machine.

For a beginner, an AC-only electrode welding machine is very economical. The Lincoln AC 225 is Lincoln’s best-selling arc welder of all time. The downside to using an electrode welder for typical artwork is that much of time, the smaller pieces are just tacked together. And, in my opinion, a wire welder or MIG welder is a little better at getting the arc started in exactly the right spot than a stick welder.

When to use TIG Welders in Art?

TIG welding allows for spatter-free, visually appealing welds. Art is visually appealing, and pretty welds are an art form to many of us. The TIG bead, if done well, will not need grinding.

If you work in non-ferrous metals such as copper, aluminum or magnesium you need a TIG welder. A MIG welder can weld aluminum and do a great job, but TIG is the option for you for copper and magnesium.

TIP: For additional information for the beginner welder read: What do I need to start welding?

Reading List

• What are the causes of welding spatter?
• How to select Welding Amperage?
• 5 Beginner Welding Mistakes
• How to Use a Plasma Cutter?
• The Best Welding Machine for Beginners
• Beginner Projects for New Welders
• Best Boots for Welding
• Why do welders wear welding caps?
• 10 Best Welding Helmets for the Beginner
• My 15 Gadgets for the Hobby Welder
• What Is Welding porosity

The post Best Methods and Metal for Welding Art Projects appeared first on Beginner Welding Guide.