Plug welds, first try

The Everlast trailer-build videos on youtube inspired me to try some plug welds. Drilled a series of holes in 3/32 angle and nested another piece of angle underneath, looked up settings on a MIG calculator, and started welding.

I thought it was going well enough- I was getting the dome recommended in the videos, and was feeling pretty good about the whole deal... then I got a wire wheel after it, and found a dimple on each one.

Did I read somewhere that spatter and the dimple is a sign of too much heat?

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Originally Posted by DaveO

The Everlast trailer-build videos on youtube inspired me to try some plug welds. Drilled a series of holes in 3/32 angle and nested another piece of angle underneath, looked up settings on a MIG calculator, and started welding.

I thought it was going well enough- I was getting the dome recommended in the videos, and was feeling pretty good about the whole deal... then I got a wire wheel after it, and found a dimple on each one.

Did I read somewhere that spatter and the dimple is a sign of too much heat?

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Those look pretty good. The edges on a couple are not quite filled. The Dimple is normal. It's the same as a small crater and one reason you dome, so it doesn't leave a concave depression below the seam. You try to minimize it, but there will always be a tiny bit of cratering with mig.

Spatter can be a result of a cold start, or from a gun angle a little off.

Well, thank you, Mark, I thought I'd totally barked it. You're right, I realized while welding that the edges were yet another detail to keep an eye on.

Is that you in the Everlast videos, BTW?

Did you fill the hole using the same technique you'd use to fill a dessert dish with frozen yogurt (start on the outer perimeter and work inward in a circular motion towards the center), or did you just aim for the center and pull the trigger? It's common to just aim for the center and pull the trigger, and while you could argue it's effectiveness (I guess), the first method is the correct and only real way to insure that both layers are fully joined (you still get the dimple in the middle). I didn't mean to imply that you didn't know any of this or that I'm talking down to you. I was just curious, that's all. I've seen more than a few plug welds break and the second method was always used in those cases.

I can't say that I've done much plug welding on thicker material, but I've done a ton of sheet metal plug welds on automotive and HVAC related items. It always seems like you can't move fast enough when plug welding then sheet metal (even when you're hauling butt), and they never show up 2 or 3 at a time.....There's always a million holes to fill!:O

I really need to start watching the Everlast videos on this trailer build. I haven't seen any of them and I'd like to see how they built their trailer.

Dave,
That's me.

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Originally Posted by youngnstudly

Did you fill the hole using the same technique you'd use to fill a dessert dish with frozen yogurt (start on the outer perimeter and work inward in a circular motion towards the center), or did you just aim for the center and pull the trigger? It's common to just aim for the center and pull the trigger, and while you could argue it's effectiveness (I guess), the first method is the correct and only real way to insure that both layers are fully joined (you still get the dimple in the middle). I didn't mean to imply that you didn't know any of this or that I'm talking down to you. I was just curious, that's all. I've seen more than a few plug welds break and the second method was always used in those cases.

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My recollection from the video (and the method I used) was to start at the middle of the hole on the lower plate and make circular motions outward, eventually reaching the perimeter of the hole and bonding to the upper plate that way. Then move the arc to the center to pile up some filler metal for the dome effect. I just went back to check the Everlast video- it's part 3, and the plug weld explanation starts at about time index 2:20. I was thinking it would be interesting to cut a plug weld apart to look at it in cross section.

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Originally Posted by youngnstudly

I really need to start watching the Everlast videos on this trailer build. I haven't seen any of them and I'd like to see how they built their trailer.

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It's a great series of videos, with about a thousand tips and tricks sprinkled throughout. Definitely worth watching... plus it's how you qualify for the current contest! :)

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Originally Posted by DaveO

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It's a great series of videos, with about a thousand tips and tricks sprinkled throughout. Definitely worth watching... plus it's how you qualify for the current contest! :)

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^^^^^^ :P

Mark, great vids man!

Dave, nice plug welds too! :cool:

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Originally Posted by DaveO

Definitely worth watching... plus it's how you qualify for the current contest! :)

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SHHH! Next thing you know, you'll be linking to the thread with the instructions!

http://www.everlastgenerators.com/fo...October-1-2013

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Originally Posted by DaveO

My recollection from the video (and the method I used) was to start at the middle of the hole on the lower plate and make circular motions outward, eventually reaching the perimeter of the hole and bonding to the upper plate that way. Then move the arc to the center to pile up some filler metal for the dome effect. I just went back to check the Everlast video- it's part 3, and the plug weld explanation starts at about time index 2:20. I was thinking it would be interesting to cut a plug weld apart to look at it in cross section.


It's a great series of videos, with about a thousand tips and tricks sprinkled throughout. Definitely worth watching... plus it's how you qualify for the current contest! :)

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That sounds like pretty much the same method actually. The main idea is to make the circular motion around the perimeter and end in the center. The method that can fail is the one I mentioned previously where the person welding leaves the stinger stationary and just pulls the trigger for a second. That can leave the edge of the hole unwelded and cause insufficient penetration. I had a bunch of plug welds to re-weld after someone at my previous job hacked everything together on some 16ga stainless. If you followed what Everlast put in their video, you can be sure their method is correct.

I built a trailer that is nearly the same as theirs (many years back) and I always like to see other methods of construction. I didn't really know what I was doing (outside of the welding part) as I was a junior or senior in high school. It came out nice, but after all these years of welding and fabrication work, I look at it once in a while and think "Why didn't I do that a little differently?" Oh well, live and learn!;)

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Originally Posted by joshuab

SHHH! Next thing you know, you'll be linking to the thread with the instructions!

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JB, are you referring to the part that says "You must also read/like and comment on 5 articles on Facebook OR watch/like/comment on 4 videos on our Everlast Generators channel or any combination as long as it reaches 5 total in combination."

Dang, you weren't supposed to tell everyone! But I guess the contest will be more fun if more than two people qualify.

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Originally Posted by youngnstudly

I built a trailer that is nearly the same as theirs (many years back) and I always like to see other methods of construction.

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Good on ya. I considered building one, using my standard "how tough could it be" logic. I've come to realize that whenever I ask "how tough could it be" I always find out EXACTLY how tough it can be, never in a good way.

I was just trying to be helpful. You're giving away the farm!

That's right, if you read or watch it, be sure to like and comment on it. Thems the rules.

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Originally Posted by performance

That's right, if you read or watch it, be sure to like and comment on it. Thems the rules.

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Dang, I almost screwed the pooch by glossing over that one little word there.

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Originally Posted by redbeard

Dang, I almost screwed the pooch by glossing over that one little word there.

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Well, if you win, we can talk about my cut...